Abstract: This study examines the influence of ceramic coatings on aluminum alloy that has been reinforced with boron carbide and tungsten carbide, using the plasma spray technique. The samples were produced by sand casting, with 100% aluminum 7475 alloy used for certain samples, and metal matrix composites consisting of 94% aluminum 7475, 3% boron carbide, and 3% tungsten carbide used for others. Following that, zirconia coatings were administered utilizing the plasma spray technique. The study evaluated the Brinell hardness, corrosion behavior by salt spray testing, wear resistance using a pin-on device, and microstructural parameters of the three sample combinations. The results demonstrate that the zirconia-coated samples had increased hardness and greater resistance to corrosion in comparison to the untreated samples. The microstructural study showed a consistently small-grained structure in the samples with a metal matrix coated with zirconia. This indicates that the samples had superior heat barrier capabilities. The compact grain structure resulted in enhanced hardness and consequent resistance to wear in the coated specimens. This study highlights the effectiveness of ceramic coatings, specifically zirconia, in improving the mechanical and corrosion properties of aluminum alloys that are strengthened with boron carbide and tungsten carbide. Therefore, these coatings have considerable potential for various industrial applications.

Keywords: Ceramic coatings, Aluminum alloy, Boron carbide, Tungsten carbide, Plasma spray technique, Corrosion resistance, Microstructure, Zirconia, Wear resistance

| DOI: 10.17148/IARJSET.2024.11638