Plasma Spraying of Red Mud-Fly Ash Mixture on Metals - An experimental study

Abstract

In spite of all its advantages, plasma spray coatings find limited applications/ adoption .One of the reasons for this is the high cost of the spray grade powders required for coating. This problem can be addressed to by exploring the possibility of using some industrial wastes as coating material. The present work aims at developing and studying the coatings of two abundant industrial wastes (Redmud and Flyash from aluminium extraction industries) on metal substrates. Conventional atmospheric plasma spray technique has been used to develop coatings of these materials. Coatings of various operating parameters were prepared and characterized. The studies conducted on the coating include X-ray diffraction technique, Microhardness measurement, etc. It is observed that the coating hardness improves with increase in coating power level.

This work establishes Redmud-Flyash mixture as a potential coating material, suitable for plasma spraying and for wear resistant applications . It also opens up a new pathway for value added utilization of these industrial wastes