Technische Universität Chemnitz
In materials engineering, surface modification is a key strategy for tailoring the performance of materials in demanding applications. For powders, especially coatings are essential in improving reinforcement-matrix bonding in metal matrix composites, providing oxidation resistance, enhancing flowability, and adding functionalities such as conductivity, wettability, or biocompatibility. Over the years, several coating methods have been explored, but each has drawbacks. Electroless plating, for example, can achieve conformal layers but relies on complex chemical baths, generates waste, and makes it difficult to control thickness. On the other hand, Physical Vapor Deposition (PVD) methods are line-of-sight processes, making them less suitable for irregular or agglomerated powders. Chemical Vapor Deposition (CVD) offers better conformality and precise control over the deposited layer, but conventional powder setups usually keep the particles static. As a result, exposure of these particles to the vaporized precursor is uneven, and the coatings produced are often inconsistent, limiting the functional properties and reliability of the powders in later processing steps. To address this limitation, a rotating mixer that can be fitted into horizontal CVD chambers has been designed and developed in this research work. The device improves precursor-particle interactions by keeping the powders in motion during deposition. It also ensures a more uniform coating over the entire surface of each particle and across the powder batch. The mixer design was created in Autodesk Fusion 360, while thermo-structural analyses were performed in ANSYS Workbench to evaluate mechanical integrity under operating conditions and to guide material and process parameter validation. The system is compact and portable, allowing it to be integrated into existing horizontal CVD reactors with minimal modification and without significant additional cost. As a proof-of-concept to demonstrate the feasibility of the setup and provide an initial validation of the coating approach, pure metallic copper (Cu) and titanium (Ti) powders were coated with thin ceramic layers of alumina (Al2O3) and yttrium oxide (Y2O3) and subsequently characterized. A simplified mixer design was used for these initial experiments instead of the final version with intricate features and geometries that require 3D printing and would have been more expensive at this early research stage. This simplified version was intended to verify that the rotating mechanism of the mixer can induce powder motion and improve the coating coverage around the particle surface. This way, the simplified setup provided a cost-effective way to test the developed approach and evaluate its performance. The more advanced design will be implemented in future trials to verify coating homogeneity, assess layer thickness control, study uniformity across different particle sizes, and evaluate the scalability of the method under realistic CVD conditions. SEM and surface morphology analyses of these coated particles revealed a more uniform coating than static powder CVD coatings. Complementary techniques, including simultaneous thermal analysis (STA), X-ray diffraction (XRD), and Raman spectroscopy, provided further insights into coating stability, phase composition, and bonding characteristics. These results show that the rotating mixer has strong potential to overcome a key limitation in powder coatings by conventional CVD systems and enable more reliable and scalable coating strategies. The potential applications of this research are vast, including metal matrix composites, where coated ceramic reinforcements improve interfacial bonding, and additive manufacturing and biomedical powders, where uniform coatings are critical for processing and functional performance.
Abstract
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Poster
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