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The need for new solutions for electrical insulation is growing due to the increased electrification in numerous industrial sectors, opening the door for innovation. Plasma spraying is a fast and efficient way to deposit various ceramics as electrical insulators, which are used in conditions where polymers are not suitable. Alumina (Al2O3) is among the most employed ceramics in the coating industry since it exhibits good dielectric properties, high hardness, and high melting point, while still being cost-effective. Various parameters (e.g., feedstock type, spray distance, plasma power) significantly influence the resulting coating in terms of microstructure, porosity, and metastable phase formation. Consequently, these parameters need to be investigated to estimate the impact on the dielectric properties of plasma-sprayed alumina coatings. In this work, alumina coatings with different spray distances have been prepared via atmospheric plasma spray (APS) on copper substrates. The microstructure, porosity, and corresponding phase formation have been analyzed with optical microscopy, X-ray diffraction (XRD), and scanning electron microscopy (SEM). Moreover, we present an in-depth analysis of the fundamental dielectric properties e.g., direct current (DC) resistance, breakdown strength, dielectric loss tangent, and permittivity. Our results show that decreasing spray distance reduces the resistivity from 6.31 × 109 Ωm (130 mm) to 6.33 × 108 Ωm (70 mm), while at the same time enhances the formation of the metastable δ-Al2O3 phase. Furthermore, space charge polarization is determined as the main polarization mechanism at low frequencies.
A series of Mg₁₋ₓZnₓTiO₃, x = 0–0.5 (MZT0–MZT0.5) ceramics was synthesised and characterised. The dielectric properties of the samples in the frequency range of
1 Hz – 7.7 GHz were explored using three different methods:
a contacting electrode method, a parallel-plate method and a perturbed resonator method. The electrical properties in the space charge and dipolar polarisation frequency ranges are discussed in relation to the phase composition and microstructure data. Differences in the zinc Substitution divided the dielectrics into two groups, namely MZT0-MZT0.2 and MZT0.3–MZT0.5, each with different amount of a main Mg₁₋ₓZnₓTiO₃ solid solution phase and a secondary solid solution phase. Zinc substitution promoted the density of the ceramics, improved the purity of the main phase and increased the permittivity for frequencies up to 10⁸ Hz, but reduced the permittivity in the microwave range. In the MZT0.3–MZT0.5 samples, for frequencies less than 1 MHz the quality (Q x ƒ) factors were lower and log σ ₐ.c, the AC conductivity, was higher than for the MZT0–MZT0.2 samples. Above 10 MHz, the (Q x ƒ) factors and log σ ₐ.c of the two groups were similar.
Thermal spraying enables a fast and propelling way to additively deposit various ceramics as electric insulators, which are used in conditions where polymers are not suitable. Alumina (Al2O3) is among the most employed materials in the coating industry since it exhibits good dielectric properties, high hardness, high melting point while still being cost-effective. Various parameters (e.g. feedstock type, plasma gas mixture, plasma power) significantly influence the resulting coating in terms of microstructure, porosity, crystallinity, and degree of un-or molten particles. As a consequence, these parameters need to be investigated to estimate the impact on the electrical insulating properties of thermally sprayed alumina. This study focuses on the development of a novel electric insulation coating from Al2O3 feedstock powders deposited via atmospheric plasma spray (APS). The microstructure, porosity, and corresponding crystallographic phases have been analyzed with optical microscopy, XRD, and SEM images. To achieve an understanding of the parameters influencing the electrical insulation performance of the manufactured coatings, an in-depth analysis of the fundamental dielectric parameters e.g., DC resistance, breakdown strength, dielectric loss tangent, permittivity is presented.