Preparation and Properties of Plasma-sprayed Al2O3-40%TiO2 Reinforced PTFE Non-stick Coating

CAO Dahua; GAO Yan; LUO Xiaotao; SHEN Jihao; CHENG Zhixi; WAN Peng; LI Hongwei

doi:10.16490/j.cnki.issn.1001-3660.2026.03.019

PDF(10818 KB)

Surface Technology ›› 2026, Vol. 55 ›› Issue (3) : 252-261. DOI: 10.16490/j.cnki.issn.1001-3660.2026.03.019

Thermal Spraying and Cold Spraying Technology

Preparation and Properties of Plasma-sprayed Al₂O₃-40%TiO₂ Reinforced PTFE Non-stick Coating

CAO Dahua^1,2, GAO Yan¹, LUO Xiaotao³, SHEN Jihao³, CHENG Zhixi², WAN Peng², LI Hongwei²

Author information +

History +

Abstract

Polytetrafluoroethylene (PTFE)-based non-stick coatings are widely used in cookware, however, they suffer from poor wear resistance and a rapid decline in hydrophobicity upon surface wear. In the present work, a novel structural design in which the PTFE coating is reinforced with discrete Al₂O₃-40%TiO₂ (AT40) ceramic protrusions is proposed to improve the wear resistance. During friction, the high-hardness ceramic protrusions support the friction counterpart to prevent rapid wear loss of the PTFE and thereby enhancing the wear resistance of the non-stick coating and improving durable non-stick performance. Firstly, a dense AT40 coating is prepared on the 304SS substrate surface in order to improve the corrosion resistance of the composite coating with the roughness of Ra 6.5 μm. Secondly, semi-molten AT40 particles are deposited via plasma spraying to prepare an AT40 ceramic coating of high surface roughness with numerous AT40 mounds on the surface. Subsequently, PTFE is used to fill the gaps between the semi-molten AT40 particle mounds to form a composite coating. The influence of spraying distance on the surface structure of the AT40 coating is investigated, and the mechanism how the surface roughness of the AT40 coating affects the wear resistance and long-term non-stick performance of the composite coating is elucidated. Additionally, characterization of the AT40 coating surface morphology and roughness is performed with a laser confocal microscope and the cross-sectional microstructure and surface morphology of the composite coating are characterized by scanning electron microscopy. The porosity of the dense coating is quantified using image analysis. The durable non-stick property of the composite coating is characterized by evaluating both wear resistance and variations in water contact angle (WCA) before and after abrasion. Wear mechanism and surface structure evolution of the composite coating during the wear process are also investigated.
Results show that the bilayer AT40/PTFE composite coating with high roughness can be fabricated through hybrid plasma spraying and PTFE deposition. Under optimized parameters, the coating exhibits excellent interfacial bonding and defect-free internal structure without micro cracks or delamination. As the spraying distance increases from 40 mm to 80 mm, 120 mm, and 150 mm, the surface roughness of the plasma-sprayed AT40 ceramic coating initially decreases and then increases, which is highly dependent on the molten-state and impact velocity of the AT40 particles. At a spraying distance of 40 mm, the roughness reaches its maximum value at Ra 19.3 μm and R_z 220.4 μm. Wear resistance of monolithic PTFE coating versus AT40/PTFE bilayer coating is comparatively investigated through ball-on-disk tribological testing, the monolithic PTFE coating directly applied on grit-blasted 304SS exhibits a rapid friction coefficient surge from 0.20 to approximately 0.65 after only 5 000 cycles, indicating complete coating depletion. In contrast, the optimized AT40/PTFE bilayers sprayed in the distance of 40mm maintains a stable and low friction coefficient (below 0.5) even after only 25 000 cycles. Furthermore, wettability tests reveal that for the optimized AT40/PTFE composite coating, the water contact angle (WCA) only decreases from 133^o to 101^o even after 25 000 cycles of standard friction while the contact angle of the conventional glass micro-ball reinforced PTFE decreases from 118^o to 45^o only after 5 000 cycles. This validates that the AT40/PTFE composite coating possesses significantly enhanced durable non-stick performance, offering a service life more than five times longer than that of the monolithic PTFE coating.

Key words

plasma spraying / Al₂O₃-40%TiO₂/PTFE composite coating / micro surface protrusion / wear resistance / durable hydrophobicity

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

CAO Dahua, GAO Yan, LUO Xiaotao, SHEN Jihao, CHENG Zhixi, WAN Peng, LI Hongwei. Preparation and Properties of Plasma-sprayed Al₂O₃-40%TiO₂ Reinforced PTFE Non-stick Coating[J]. Surface Technology. 2026, 55(3): 252-261

References

[1] 江雷. 从自然到仿生的超疏水纳米界面材料[J]. 科技导报, 2005, 23(2): 4-8.
JIANG L.Super-Hydrophobic Nanoscale Interface Materials: From Natural to Artificial[J]. Science & Technology Review, 2005, 23(2): 4-8.
[2] 伍大恒, 刘文静, 吴斌, 等. 极端低温环境下防覆冰材料研究进展[J]. 表面技术, 2022, 51(6): 1-13.
WU D H, LIU W J, WU B, et al.Research Progress of Anti-Icing/Icephobic Materials for Extreme Low Temperature Environments[J]. Surface Technology, 2022, 51(6): 1-13.
[3] MIZUTA, YOSHIHIKO AND NORIHISA ISOMURA. Influence of the Fin Stocks Surface Treatment on Frost and Defrost Characteristics of the Heat Exchangers for the Room Air-Conditioners[J]. Sumitomo Light Metal Technical Reports, 2013, 54(1): 30-36.
[4] ASHOK D, CHEESEMAN S, WANG Y, et al.Superhydrophobic Surfaces to Combat Bacterial Surface Colonization[J]. Advanced Materials Interfaces, 2023, 10(24): 2300324.
[5] 陈耀峰, 邵文鹏, 赵广宾, 等. 金属基体表面超疏水涂层材料的制备及应用研究进展[J]. 材料研究与应用, 2024, 18(1): 106-115.
CHEN Y F, SHAO W P, ZHAO G B, et al.Research Progress on the Preparation and Application of Superhydrophobic Coating Materials on Metal Substrate Surface[J]. Materials Research and Application, 2024, 18(1): 106-115.
[6] 于莹. 2014全国炊具行业情况调查及工作报告[J]. 五金科技, 2015(2): 12-16.
YU Y.2014 National Cooking Utensil Industry Survey and Work Report[J]. Hardware Science and Technology, 2015(2): 12-16.
[7] 张帆. 氟硅低表面能交联网络涂层制备及性能研究[D]. 上海: 上海大学, 2014 : 12-16.
ZHANG F.Preparation and Performance of Fluorine/silicone Crosslinked Network Coatings with Low Surface Energy for Marine Antifouling Application[D]. Shanghai: Shanghai University, 2014: 12-16.
[8] 吴宏博, 丁新静, 于敬晖, 等. 有机硅树脂的种类、性能及应用[J]. 纤维复合材料, 2006, 23(2): 55-59.
WU H B, DING X J, YU J H, et al.Varieties, Properties and Application of Organic Silicone Resin[J]. Fiber Composites, 2006, 23(2): 55-59.
[9] 宋小飞. 有机硅改性聚氨酯及其船舶防污涂层的性能研究[D]. 大连: 大连海事大学, 2016: 2-5.
SONG X F.Property Research of Polydimethylsiloxane Modified Polyurethane and Its Marine Antifouling Coatings[D]. Dalian: Dalian Maritime University, 2016: 2-5.
[10] 邵晓燕. 无机物/有机物复合疏水耐磨涂层的制备及其性能研究[D]. 北京: 中国地质大学(北京), 2020: 4-5.
SHAO X Y.Preparation and Properties of Inorganic/Organic Hydrophobicity and Wear Resistance Composite Coatings[D]. Beijing: China University of Geosciences, 2020: 4-5.
[11] HUANG J Y, LAI Y K, PAN F, et al.Multifunctional Superamphiphobic TiO₂ Nanostructure Surfaces with Facile Wettability and Adhesion Engineering[J]. Small, 2014, 10(23): 4865-4873.
[12] LI S H, HUANG J Y, GE M Z, et al.Controlled Grafting Superhydrophobic Cellulose Surface with Environmentally-Friendly Short Fluoroalkyl Chains by ATRP[J]. Materials & Design, 2015, 85: 815-822.
[13] SHATERI-KHALILABAD M, YAZDANSHENAS M E.One-Pot Sonochemical Synthesis of Superhydrophobic Organic-Inorganic Hybrid Coatings on Cotton Cellulose[J]. Cellulose, 2013, 20(6): 3039-3051.
[14] KANG A S, GREWAL J S, CHEEMA G S.Effect of Thermal Spray Coatings on Wear Behavior of High Tensile Steel Applicable for Tiller Blades[J]. Materials Today: Proceedings, 2017, 4(2): 95-103.
[15] KAUR S, BALA N, KHOSLA C.Investigations of Thermal Sprayed HAP and HAP-TiO₂ Composite Coatings for Biomedical Applications[J]. Anti-Corrosion Methods and Materials, 2019, 66(1): 74-87.
[16] 李长久. 热喷涂技术应用及研究进展与挑战[J]. 热喷涂技术, 2018, 10(4): 1-22.
LI C J.Applications, Research Progresses and Future Challenges of Thermal Spray Technology[J]. Thermal Spray Technology, 2018, 10(4): 1-22.
[17] MEGHWAL A, ANUPAM A, MURTY B S, et al.Thermal Spray High-Entropy Alloy Coatings: A Review[J]. Journal of Thermal Spray Technology, 2020, 29(5): 857-893.
[18] Biomaterials: Thermal Spray Processes and Applications[J]. Journal of Thermal Spray Technology, 2018, 27(8): 1205-1211.
[19] RAVI SHANKAR A, JAGADEESWARA RAO C, VETRIVENDAN E, et al.Evaluation of Thermal Spray Alumina Coatings on Nickel Electrode Connector for Reprocessing Applications[J]. Transactions of the Indian Institute of Metals, 2018, 71(2): 297-307.
[20] 张红松, 刘振启, 关绍康. 等离子喷涂纳米与微米YSZ热障涂层的孔隙结构比较[J]. 表面技术, 2010, 39(5): 4-7.
ZHANG H S, LIU Z Q, GUAN S K.Comparison of Pore Structure between Plasma-Sprayed Nano-YSZ and Micron-YSZ Thermal Barrier Coatings[J]. Surface Technology, 2010, 39(5): 4-7.
[21] LI S P, LUO X T, LI C J.Cold Sprayed Superhydrophilic Porous Metallic Coating for Enhancing the Critical Heat Flux of the Pressurized Water-Cooled Reactor Vessel in Nuclear Power Plants[J]. Surface and Coatings Technology, 2021, 422: 127519.
[22] LIU M, PENG Q Q, HUANG Y F, et al.Influencing Factors and Process Optimization of Al/SiC Powder-Cored Wires by Plasma Transferred Wire Arc Spraying[J]. Journal of Thermal Spray Technology, 2024, 33(6): 2167-2183.
[23] KUMARI R.Plasma-Sprayed Al₂O₃-TiO₂-YSZ Composite Coating on EN31 Steel: Microstructural and Tribological Properties for Improved Agricultural Tool Durability[J]. Journal of Materials Engineering and Performance, 2025, 34(23): 28855-28866.
[24] 赵乐. 超疏水材料及其涂层的研究进展[J]. 表面技术, 2024, 53(24): 54-68.
ZHAO L.Research Progress of Superhydrophobic Materials and Their Coatings[J]. Surface Technology, 2024, 53(24): 54-68.
[25] KATARIA S, JAIN S, SIKARWAR B S, et al.Plasma Techniques for the Fabrication of Hydrophobic Substrates[M]//Recent Advances in Mechanical Engineering. Singapore: Springer Nature Singapore, 2023: 831-846.
[26] XIAO J Y, PAN J J, GUO H Z, et al.Numerical and Experimental Analyses of Deposition Characteristics of Plasma-Sprayed Al₂O₃-40%TiO₂ on Different Substrates[J]. The International Journal of Advanced Manufacturing Technology, 2022, 120(9): 6393-6405.
[27] 章玉丹. 聚四氟乙烯基超声电机耐磨涂层的研究[D]. 南京: 南京航空航天大学, 2015: 53-55.
ZHANG Y D.Research on the PTFE-Based Wear-Resistant Coating for Ultrasonic Motors. Nanjing: Nanjing University of Aeronautics and Astronautics, 2015: 53-55.
[28] 杨浩, 卞达, 郭永信, 等. Al₂O₃改性聚四氟乙烯复合涂层的摩擦磨损特性[J]. 材料保护, 2020, 53(10): 43-46.
YANG H, BIAN D, GUO Y X, et al.Friction and Wear Characteristics of Al₂O₃ Modified Polytetrafluoroethylene Composite Coatings[J]. Materials Protection, 2020, 53(10): 43-46.