Effect of Si content on the microstructure and properties of Ti–Si–C composite coatings prepared by reactive plasma spraying

Abstract In this study, Ti–Si–C composite coatings were synthesized via plasma spraying of agglomerated powders prepared by a spray drying/precursor pyrolysis technology using Ti, Si, and sucrose powders. The influence of Si content, ranging from 0 wt% to 24 wt%, on the microstructure, mechanical properties, and oxidation resistance of the composite coatings was investigated. Results show that the phase composition of the Ti–Si–C composite coatings changes with the increasing Si content. The coatings without Si addition consist of TiC and Ti3O; the coatings with 6–18 wt% Si are composed of TiC, Ti5Si3, and Ti3O; the coatings with Si content of 24 wt% form only TiC and Ti5Si3 phases. As the Si content increases, the hardness of the Ti–Si–C composite coatings increases first and then decreases, depending on the intrinsic hardness of the ceramic phases, the brittleness of Ti5Si3, and the defects such as pores and cracks. The Ti–Si–C composite coatings have high wear resistance due to the in-situ synthesized high-hardness TiC and Ti5Si3. Owing to the high brittleness of Ti5Si3, the increasing Si content leads to higher wear volume loss at room temperature, which can be partially improved in high-temperature wear tests. The oxidation resistance of Ti–Si–C composite coatings increases with the increase of Si content, and the higher the oxidation temperature, the more obvious the influence of the Si addition on oxidation resistance.