Microstructure and photocatalytic activity of APS coatings obtained from different TiO2 nanopowders

Abstract

In recent years, intense research has shown that thermal spray techniques, especially atmospheric plasma spraying (APS), can be used to obtain nanostructured TiO2 coatings with effective photocatalytic activity. This study compares the photocatalytic activity of APS coatings obtained from different powders: two nanostructured TiO2 powders produced by spray-drying of two TiO2 nanosuspensions with different solids contents, one spray-dried powder obtained from a suspension comprising a mixture of submicronic and nanometric TiO2 particles and finally one commercial, nanostructured, TiO2 spray-dried powder. All powders were characterised by XRD, FEG-ESEM, granule size distribution, and a flowability evaluation. Feedstock powders were then deposited on austenitic stainless steel coupons using APS. Hydrogen or helium was used as secondary plasma gas. Coating microstructure and phase composition were characterised using FEG-ESEM and XRD techniques; coating anatase content was quantified by the Rietveld method.

A significant amount of anatase to rutile transformation was found to take place during the plasma spraying process. In general, the coatings had a bimodal microstructure characterised by the presence of completely fused areas in addition to non-molten areas consisting of agglomerates of anatase nanoparticles. Results also showed that anatase content and porosity of the coatings largely depend on the secondary plasma gas nature, as well as on the characteristics of the feedstock.

Finally the photocatalytic activity of the coatings was determined by measuring the degradation of methylene blue dye in an aqueous solution. A reasonably good fit of a first-order kinetic model to the experimental data was found for all coatings. The values of the kinetic constant were related to feedstock characteristics as well as to plasma spraying conditions. (C) 2012 Elsevier B.V. All rights reserved.