Large area deposition of graphene-containing coatings for diverse functional applications

Purpose and goal

Aim was the development of graphene-containing coatings by applying thermal spraying and a novel hybrid approach by employing powder along with graphene suspension. Spray trials by use of suspension plasma spraying of graphene-containing mixed suspensions, hybrid spraying of matrix material powder and graphene suspension, and plasma spraying, HVOF and HVAF spraying of powder/graphene platelet blends were performed. The results show that coatings with incorporated graphene can be produced, and that the wear performance can be better for graphene-containing coatings.

Expected results and effects

Surface coatings represent one of six subject areas identified by SIO Grafen and the proven ability to incorporate graphene into thermal spray coatings makes this project extremely relevant. The results of the project can form the basis for an increased use of graphene in coatings in order to exploit the unique advantages of graphene in technological applications. This is in line with SIO Grafen´s vision for 2030 to make Sweden one of the top ten countries in the world for the use of graphene in industrial applications.

Planned approach and implementation

Spray trials by use of SPS of graphene-containing mixed suspensions, hybrid spraying of matrix material powder and graphene suspension, and APS, HVOF and HVAF of powder/graphene platelet blends were performed. The results showed that the graphene platelets could be successfully incorporated in both metallic and ceramic matrix materials by using them as a suspension feedstock. However, the GNPs are partially agglomerated, which can possibly be prevented by a smaller platelet size. Tribo-tests have already shown better performance of the graphene-containing coatings.