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<p>The inherently insulating nature of alumina (Al<sub>2</sub>O<sub>3</sub>), despite its outstanding mechanical and thermal properties, restricts its use in electrically functional ceramic applications. This study explores the development of electrically conductive and mechanically robust alumina coatings by incorporating graphene nanoplatelets (GNPs) via atmospheric plasma spraying (APS) technique. Composite powders with 0.5&#xa0;wt% and 1&#xa0;wt% GNPs were prepared and deposited on stainless steel substrates. The influence of GNP addition on powder flowability, coating microstructure, adhesion strength, phase composition, and electrical conductivity was systematically investigated. Results revealed that GNPs significantly improved powder flow, coating density, surface quality, and inter-splat bonding due to their lubricating and thermally conductive properties. Raman analysis confirmed the structural survival of graphene post-spraying. Most notably, electrical conductivity increased from 1.54&#xa0;S&#xa0;m<sup>−1</sup> for pure alumina to 26.38&#xa0;S&#xa0;m<sup>−1</sup> for the 1&#xa0;wt% GNP coating, indicating the formation of percolative conductive networks. These findings demonstrate the potential of GNP-reinforced alumina coatings for multifunctional applications, including electronic modules, fuel cell electrodes, wear-resistant surface, and high-performance thermal systems.</p>

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Microstructural and Functional Enhancement of Plasma-Sprayed Alumina Coatings via Graphene Nanoplatelet Reinforcement for Next-Generation Electrical Equipment

  • 期刊论文

  • 发表日期：

    2026年5月26日

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  • Puja Keshri,
  • Ambarisha Mishra

摘要

The inherently insulating nature of alumina (Al2O3), despite its outstanding mechanical and thermal properties, restricts its use in electrically functional ceramic applications. This study explores the development of electrically conductive and mechanically robust alumina coatings by incorporating graphene nanoplatelets (GNPs) via atmospheric plasma spraying (APS) technique. Composite powders with 0.5 wt% and 1 wt% GNPs were prepared and deposited on stainless steel substrates. The influence of GNP addition on powder flowability, coating microstructure, adhesion strength, phase composition, and electrical conductivity was systematically investigated. Results revealed that GNPs significantly improved powder flow, coating density, surface quality, and inter-splat bonding due to their lubricating and thermally conductive properties. Raman analysis confirmed the structural survival of graphene post-spraying. Most notably, electrical conductivity increased from 1.54 S m−1 for pure alumina to 26.38 S m−1 for the 1 wt% GNP coating, indicating the formation of percolative conductive networks. These findings demonstrate the potential of GNP-reinforced alumina coatings for multifunctional applications, including electronic modules, fuel cell electrodes, wear-resistant surface, and high-performance thermal systems.