本研究使用大氣電漿噴塗製程技術，於中碳鋼底材上披覆氧化鋁基熔射塗層；塗層與底材間披覆中介層以增加塗層與底材間之黏結性。研究的目標有二：(1)探討塗層熱衝擊破壞機構，(2) 以不同電流製備進行熔射塗層磨耗試驗，並從顯微結構，相結構，顯微硬度值，摩擦係數，來探討其磨耗機構。
研究設備有X光繞射儀，場發射型掃瞄式電子顯微鏡，環境掃描式電子顯微鏡，維克氏顯微硬度機，表面粗度儀，大氣熱處理爐，SRV磨耗試驗機。
由實驗結果得知：(1) 氧化鋁基熔射塗層隨著氧化鈦比例提升，塗層硬度值分佈範圍變大，奈米尺度結構塗層由於團聚造粒時成分均勻分佈，所以塗層硬度分佈範圍相對小。(2) 塗層受熱衝擊破壞，大裂痕主要從陶瓷塗層和中介層間產生，隨著氧化鈦比例提升塗層內部也會在氧化鋁和氧化鈦交界處產生裂痕，使塗層提早失效。(3) 進行850℃熱衝擊時，氧化鋁會相變產生δ-Al2O3，非化學當量的氧化鈦也會吸收環境中氧氣形成金紅石。(4) 不同尺度結構塗層，以奈米尺度具較佳耐磨耗性，可歸因於部份融熔區，阻礙了裂痕的成長。(5)改變噴塗電流對製備塗層性質影響不大。(6) 磨潤性質方面，使用不同對手材有不同的磨耗機制產生。

The alumina-based coatings were deposited on the mild carbon steel substrates pre-coated with NiAl bondcoat by using APS system in this research. The main purpose of this research were: (1) Discussed the thermal shock failure mechanism for ceramic coatings. (2) Deposited ceramic coatings by different current to carry out wear test, and from microstructure, phase structure, micro-hardness, coefficient of friction to discuss the failure mechanism.
The experiment instrument for this research is including: X-ray Diffractometer, Enviromental Scanning Electron Microscope, Field-Emision Scanning Electron Microscope, Vickers hardness tester, Surface Profilometer, Heat-Treatment Furnace, Schwingung Reibung and Verschleiss Tester.
The results indicate that: (1) The hardness distribution of coatings were increased with increasing the ratio of titania; however the hardness distribution of the nanostructure coating prepared by agglomerated particle was more narrow. (2) The macrocrack was generated between ceramic coating and bondcoat, with increasing the ratio of titania the crack also can generated between alumina splat and titania splat, it would make coating failure more quickly. (3) After 850 ℃ thermal test alumina trasformed to δ-Al2O3, the non-stoichimatic titania also absorbed the oxygen from environment to formation of rutile. (4) The nanostructure coating had the best wear resistance among other coatings, due to its part-melted zone could arrest the crack. (5) The coatings prepared by different current had similar propertis. (6) Different wear performance was found with using different counter balls.

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