Series on Biomechanics, Vol.36 No.

2 (2022), 141-152
DOI: 10.7546/SB.36.2022.02.14

Dependence of the elasticity modulus of microplasma coatings made of

titanium grade VT1-00 and zirconium grade KTC-110 on their porosity
A. Moltasova, M. Dymana, S. Kaliuzhnyia, I. Mossokovskaa, S. Voinarovycha*,
O. Kyslytsiaa , E. Koytchevb
a
E.O. Paton Electric Welding Institute of the National Academy of Sciences of Ukraine,
11 Kazymyr Malevych St., Kyiv 03150 Ukraine; moltasov@gmail.com
b
Institute of Mechanics, Bulgarian Academy of Sciences Sofia, Acad. G Bonchev Str., bl. 4;
koytchev@imbm.bas.bg

Received: 6 April 2022 Accepted: 14 June 2022 *Corresponding Author

Abstract
This study aims to estimate a functional relationship between the modulus of elasticity and porosity of
biocompatible coatings made of titanium alloy grade VT1-00 and zirconium alloy grade KTC-110 deposited by the
microplasma method.
The main methods for determining the modulus of elasticity of plasma coatings are analyzed and their advantages
and disadvantages are presented. On the basis of the present study, a new experimental-theoretical technique was
developed, which makes it possible to determine the elasticity modulus of the coating in bending without separating
it from the substrate.
The modulus of elasticity of the coating was determined using static three-point bending (on two supports) and
calculating the desired value in the proportional range of the obtained bending diagram.
Regression dependencies that allow determining the elasticity moduli of coatings in the zone of tension and
compression were obtained, depending on the degree of their bulk porosity. The functional relationship between bulk
porosity and modulus of elasticity was established by constructing linear regression curves using the least squares
method.
Mathematical equations were obtained to determine the modulus of elasticity of the coating in explicit form
through the geometric dimensions of the coating and substrate, the modulus of elasticity of the substrate, and the
experimentally determined flexural stiffness of the entire system; the deviation of the calculated values of the modulus
of elasticity from the experimental ones did not exceed 5%.

Keywords: Titanium, zirconium, microplasma sprayed, coating, elastic modulus, porosity.

1. Introduction

Porosity is one of the most important characteristics of coatings obtained by thermal spraying process.
The degree of porosity of the coating determines not only its functional characteristics, but also its physical
and mechanical properties [1].
It has been estimated that for some ceramic, metallic, and cermet materials, the porosity value has a
significant effect on the elastic modulus value [2].
Studies of the influence of porosity on the value of the modulus of elasticity of the material have been
carried out since the 60s of the last centuries. For the first time in [3], the influence of a small volume
percentage of porosity on the elastic modulus of glass was studied, because of which an analytical
dependence was proposed for the calculation of elastic modulus with porosity of less than 2%. For the first
time, the effect of bulk porosity on the modulus of elasticity of the coating itself, rather than the bulk
material, was studied in [4] using the example of glass-ceramic coatings on a steel substrate. The results of
the studies performed showed that the modulus of elasticity of the coating decreases with an increase in
bulk porosity up to 10%.

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and zirconium grade KTC-110 on their porosity

According to the results of studies [5], it was found that the dependence of the elastic modulus of
powder coatings formed by electrocontact sintering from various steel-substrated ceramic and metal-
ceramic materials on their bulk porosity is close to linear. The porosity in this case reached 30%. However,
experience has shown that for materials with different nature of the relationship of elementary rigid
volumes, the functional dependences of the characteristics of elasticity and strength on porosity differ
significantly, and universal equations describing such dependence for bodies with an arbitrary structure
cannot be obtained [6]. Therefore, for each individual coating made from specific material using an exact
technology, the elastic modulus must be determined experimentally.
When determining the elastic characteristics of plasma coatings by conventional methods [7], some
technical difficulties arise, since most of these experience failure at very small deformations [8]. In this
regard, acoustic methods [9] are promising for determining the physico-mechanical properties of coatings,
which make it possible to determine the elastic characteristics without destroying the samples. However,
the use of these methods in the case of studying the elastic characteristics of multilayer materials obtained
by plasma spraying is associated with difficulties of separating the sprayed layer from the substrate surface,
as well as with the inaccuracies that this separation introduces [10]. Based on the above mentioned, there
is a need to develop methodology for determining the elastic characteristics of the coating without
separating it from the substrate.
In elastic deformation, to determine the physical and mechanical properties of coating, methods are
used to measure the modulus of elasticity by tensile and bending tests [11]. However, taking into account
the distribution of residual stresses in the coatings obtained by plasma spraying [12] and their effect on the
operation of the composition as a whole, bending tests turn out to be the most appropriate. It is known [13]
that for brittle and low-plastic materials, such as sprayed coatings, bending tests have successfully replaced
uniaxial tensile as such, which are not representative for them.
According to the currently existing method for calculating the physical and mechanical properties of
coatings, proposed in [14, 15], the modulus of elasticity of the coating is determined by the equation

Ec =
(
12 Bx − b  hb  Eb hb2 + 12 yb2 )
(1)
(
b  hc hc2 + 12 yc2 ) ,

where Bx is the cross-sectional stiffness of the coated sample, determined during the cantilever bend
test; b is the sample width; Eb is the modulus of elasticity of the substrate; hb is the substrate thickness;
hc is the coating thickness; yb and yc are the distances from the centers of gravity of the substrate and coating,
respectively, to the reduced center of gravity of the sample cross-section (Fig.1).

Fig.1. Schematic representation of the cross section of the sample with a coating for bending tests.

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and zirconium grade KTC-110 on their porosity

In this case, according to the data of the same works [14, 15], the distances yb and yc are determined
by the equation
Ec  hc ( hb + hc )
yb =
2 ( Eb  hb + Ec  hc )
(2)
and
hb + hc
yc = − yb
(3) 2
respectively.

If we substitute (2) and (3) into (1), then the value of Ec will be on both sides of the equation, and to
find it, it is necessary to solve an algebraic equation with respect to it. However, in [14, 15], this was not
done, and for calculation, yb and yc were given by the ratio Ec/Eb. That is, given that the modulus of elasticity
of the substrate Eb is known, in fact, it was set by the value of the modulus of elasticity of the coating Ec,
which is to be determined. It is obvious that the reliability of the calculation results by this method is
questionable. Therefore, there is a need to develop an experimental-theoretical technique that will allow
one to determine the elasticity modulus of a coating in bending in an explicit form.

2. Methods, materials, and equipment

The magnitude of the bending stiffness with respect to the main axis x, passing through the reduced
center of gravity of the sample, was determined through the stiffness with respect to the parallel axis x1, on
which the base of the section lies, according to the equation [16]

Bx = Bx1 − a 2y  A
(4)

where ay is the distance between the axes x and x1 (Fig. 1); A - stiffness in tension-compression.
Bending stiffness relative to the x1 axis was determined by the equation

hb hb + hc
1 1
b  y 2dy = b  Eb  hb3 + b  Ec ( hb + hc ) − hb3 
3
Bx1 = Eb  b  y 2 dy + Ec 
0 hb 3 3  
(5)

and the stiffness in tension, according to the equation [16]

(6)
A = Eb  b  hb + Ec  b  hc .
Since the x-axis is basic, ay is the coordinate of the reduced center of gravity of the section relative to
the x1 axis, which is determined by the equation

hb hb + hc
Eb  b  ydy + Ec  b  ydy
b  Eb  hb2 + b  Ec ( hb + hc ) − hb2 
1 1 2
S x*1 0 hb  
ay = = =2 2
(7)
A Eb  b  hb + Ec  b  hc Eb  b  hb + Ec  b  hc
S x*1
where is the reduced static moment of the section about the x1 axis, which can be found in the same
way as the geometric static moment of the area Sx1, giving each area element a weighting factor in the form
of the modulus of elasticity at the corresponding point of the section.
Substituting (5)-(7) into (4), after transformations, we obtain equation for determining the bending
stiffness
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and zirconium grade KTC-110 on their porosity

Bx =
(
b Eb2  hb4 + 4 Eb  Ec  hb3  hc + 6 Eb  Ec  hb2  hc2 + 4Eb  Ec  hb  hc3 + Ec2  hc4 )
12 ( Eb  hb + Ec  hc )
(8)

It should be noted here that for a homogeneous material (Eb = Ec = E), Eq. 8 has the form

b  ( hb + hc )
3
b  h3
Bx = E =E
(9) 12 12 .

Considering that the axial moment of inertia of a rectangular section is determined by the equation
[17]
b  h3
Jx =
12
we obtain equation for determining the bending stiffness of a section with a constant modulus of elasticity
from [16]

Bx = E  J x ,
which confirms the correctness of the Eq. 8 obtained above for the flexural rigidity of a two-layer section.

By transforming Eq. 8, we obtain the equation



( 6B 
b 
) B
hc4  Ec2 + 2hc  Eb  hb 2hb2 + 3hb  hc + 2hc2 − x  Ec + Eb2  hb4 − 12 x Eb  hb = 0
b

solving which with respect to the modulus of elasticity of the coating, we obtain

Ec =
1  6 Bx
3 b
hc 
( 
− Eb  hb 2hb2 + 3hb  hc + 2hc2  +

)
2
+
1
hc3

( )
6 Bx  Bx
 Eb  hb 2hb + 3hb  hc + 2hc − b  − Eb  hb  hc + 12 b Eb  hb  hc .

2 2

2 4 2 2

(10)

As we can see, the resulting equation makes it possible to unambiguously determine the elastic
modulus of an individual layer (coating) through the known elastic modulus of another layer (substrate),
the cross-sectional dimensions of the layers, and the bending stiffness of a two-layer sample, which must
be determined experimentally.
The experimental method for finding the modulus of elasticity of the sample consists in its static
three-point bending (Fig. 2) and the calculation of the desired value in the proportionality range of the
obtained bending diagram.

Fig. 2. Scheme of sample loading at three-point bending.

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and zirconium grade KTC-110 on their porosity

Samples with coatings obtained by sputtering Ti and Zr wires of grades VT1-00 (analogue of Ti alloy
Grade 2) and KTC-110 (analogue of Zr alloy Grade 702) with a diameter of 0.3 mm were used as objects
under study on a microplasma spraying unit MPS-004 [18] on substrate made of titanium alloy VT6
(analogue of Ti alloy Grade 5), in the form of rectangular parallelepipeds with length L = 50 ± 3 mm, width
b = 10.08 ± 0.05 mm, and substrate thickness hb = 1.96 ± 0 .04 mm and coatings hc = 0.36 ± 0.04 mm (Fig.
3a-f). The chemical composition and mechanical characteristics of the wires are presented in Tables 1 – 4.
The coatings were applied using the regime parameters of microplasma spraying, which
ensure the formation of coatings with bulk porosity for alloys of grades VT1-00 (6.5%; 13.7%; 25.0%) and
KTC-110 (2.8 %; 8.7%, 20.3%) [19, 20].

Table 1
Chemical composition of Ti and Zr wires from alloys of grades VT1-00 and KTC-110.

Alloy Zr Nb Hf Fe Ca O Si Ni C Cr Ti N H
VТ1-00 Up Up Up Up
Up to 99.58- Up to
- - - to - to - to - to
0.1 99.9 0.008
0.15 0.08 0.05 0.04
КТC-110 0.9- 0.11-
remainder 0.01 0.05 0.03 0.02 0,02 0.02 0.02 - - -
1.1 0.14

Table 2
Physical and mechanical properties of VT1-00 and KTC-110 alloys

Tensile
Melting Density, Elastic modulus Relative elongation after
Alloy strength
temperature, °C кg/м3 (E), GPа rupture (δ5), %
(σv), MPа
VТ1-00 1668 4505 112 400-450 30
КТC-110 1868 6500 99 440-450 15

To determine the modulus of elasticity of the substrate Eb, samples of the VT6 alloy without coating
(Fig. 3g) with geometric dimensions described above were used.

а) b) c)

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 A. Moltasov et al. / Dependence of the elasticity modulus of microplasma coatings made of titanium grade VT1-00
and zirconium grade KTC-110 on their porosity

d) e) f)

g)

Fig. 3. Specimens made of alloy Grade VT6 for static bending tests: a) coated with alloy grade VT1-00 with a
porosity of 6.5%; b) - with a coating alloy of grade VT1-00 with a porosity of 13.7%; c) - coated with an alloy of
grade VT1-00 with a porosity of 25.0%; d) - coated with an alloy of grade KTC-110
with a porosity of 2.8%; e) - coated with an alloy of grade KTC-110 with a porosity of 8.7%; f) - coated with an
alloy of grade KTC-110 with a porosity of 20.3%; g) - without coverage.

Mechanical tests were carried out on an universal tensile testing machine 2054 R-5 with modernized
means of registration forces and deformations, adapted to measure small elastic deformations, equipped
with special mandrel for testing three-point bending (Fig. 4a), which allows to record a bending diagram in
real time while saving data in digital format (Fig. 4b).

а) b)

Fig. 4. Experimental complex 2054 R-5: a) setup for three-point bending tests; b) computerized control unit.

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 A. Moltasov et al. / Dependence of the elasticity modulus of microplasma coatings made of titanium grade VT1-00
and zirconium grade KTC-110 on their porosity

According to the bending diagram of the samples in the range of proportionality of the bending curve,
two values of the load F1 and F2 and the deflections f1 and f2 caused by them were determined. Sample
elasticity modulus at three-point bending Eb was calculated by the equation [21]

l 3 ( F2 − F1 ) l 3 ( F2 − F1 )
EB = =
4b  h3 ( f 2 − f1 ) 4b  ( hb + hc )
3
( f 2 − f1 ) ,
(11)

where l is the distance between the supports.

Substituting (11) into (9), we obtained the flexural strength of the sample

b ( hb + hc ) l 3 ( F2 − F1 )
3
Bx = EB =
12 48 ( f 2 − f1 )
(12) .

3. Results

Based on the results of testing three samples alloy of grade VT6 (Fig. 3g), it was found that the average
value of the modulus of the substrate is Eb = 109970 MPa (Table 5).

Table 5
Modulus of elasticity alloy of grade VT6 substrate
№ sample Sample Sample Force 1 Force 2 Deflection Deflection Modulus of
width thickness (F1), Н (F2), Н 1 (f1), mm 2 (f2), mm elasticity of the
(b), mm (hb), mm substrate (Eb), МPа
Substrate 1 10.14 2.00 130 330 0.18 0.42 109970
Substrate 2 10.12 2.00 200 400 0.25 0.49 110187
Substrate 3 10.16 2.00 160 360 0.20 0.44 109754
The modulus of elasticity of the substrate was determined by Eq. 11 in the absence of a coating (hc=0).
The distance between the supports in all cases was l = 35 mm.

When determining the elastic moduli of coatings from each alloy for each of the three porosity values,
series of six samples with coatings was tested in such a way that for three samples the coating
layer was in the tension zone, and for the other three samples it was in the compression zone (Fig. 5).

а) b)

Fig. 5. Samples coated with Ti (VT1-00) after three-point bending tests: a) - coating with porosity of 6.5% was
in the tension zone; b) - coating with porosity of 25.0% was in the compression zone.

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 A. Moltasov et al. / Dependence of the elasticity modulus of microplasma coatings made of titanium grade VT1-00
and zirconium grade KTC-110 on their porosity

As a result of the tests, the load values F1 and F2 were determined, which are given in (Table 6) and
the deflections f1 and f2 caused by them (Fig. 6)

Fig. 6. Selection of points in the proportional range of the bending diagram of a sample coated with an alloy of
grade KTC-110 on a lining of an alloy of grade VT6 (the coating is in the tensile zone; its porosity is 8.7%).

Table 6
Results of calculations of the elastic moduli of coatings made the alloys of grades VT1-00 and KTC-110 with
different porosity.

Sample Тhickness Тhickness Force Deflection Bending Modulus of

width substrate сoating stiffness elasticity of
№ sample (f1), (f2),
(b), mm (hb), mm (hc), mm (F1), Н (F2), Н (Bx), the coating
mm mm Н·mm2 (Ec), МPа
Ті (ВТ1-00), porosity 6.5 %, coating in the compression zone
ТіSP-1 10.09 1.95 0.39 115 315 0.13 0.32 921814 47130
ТіSP-2 10.11 1.97 0.35 210 410 0.22 0.41 921811 47912
ТіSP-3 10.08 1.97 0.35 220 420 0.24 0.43 921814 48576
Ті (ВТ1-00), porosity 6.5 %, coating in the tensile zone
ТіST-4 10.05 1.96 0.36 170 370 0.21 0.43 794662 21349
ТіST-5 10.08 1.95 0.36 110 310 0.16 0.39 768176 17553
ТіST-6 10.07 1.96 0.35 150 350 0.19 0.41 794670 21809
Ті (ВТ1-00), porosity 13.7 %, coating in the compression zone
ТіMP-7 10.06 1.97 0.33 95 295 0.10 0.31 853526 35438
ТіMP-8 10.06 1.96 0.35 75 275 0.08 0.29 853526 35602
ТіMP-9 10.06 1.95 0.35 130 330 0.15 0.36 853526 38470
Ті (ВТ1-00), porosity 13.7 %, coating in the tensile zone
ТіMT-10 10.14 1.95 0.35 135 335 0.18 0.41 768174 17200
ТіMT-11 10.06 1.95 0.37 160 360 0.23 0.46 768172 17239
ТіMT-12 10.06 1.94 0.36 175 375 0.25 0.49 743397 14916
Ті (ВТ1-00), porosity 25.0 %, coating in the compression zone
ТіLP-13 10.14 1.97 0.38 100 300 0.11 0.33 823043 21777
ТіLP-14 10.10 1.98 0.4 90 290 0.10 0.32 823036 18723

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and zirconium grade KTC-110 on their porosity

ТіLP-15 10.12 1.99 0.37 115 315 0.13 0.35 823049 18070
Ті (ВТ1-00), porosity 25.0 %, coating in the tensile zone
ТіLT-16 10.08 1.95 0.37 75 275 0.09 0.33 743392 11780
ТіLT-17 10.10 1.94 0.36 125 325 0.16 0.40 743393 14275
ТіLT-18 10.09 1.92 0.40 150 350 0.22 0.47 720162 12255
Zr (КТC-110), porosity 2.8 %, coating in the compression zone
ZrSP-1 10.09 1.99 0.36 140 340 0.15 0.35 886357 32868
ZrSP-2 10.11 1.99 0.34 175 375 0.19 0.39 886370 35050
ZrSP-3 10.07 1.95 0.36 140 340 0.16 0.37 853527 36947
Zr (КТC-110), porosity 2.8 %, coating in the tensile zone
ZrST-4 10.09 1.97 0.34 190 390 0.25 0.48 768181 13566
ZrST-5 10.08 1.95 0.32 200 400 0.28 0.52 743499 14295
ZrST-6 10.07 1.95 0.36 150 350 0.2 0.44 743395 12378
Zr (КТC-110), porosity 8.7 %, coating in the compression zone
ZrMP-7 10.03 2.00 0.34 190 390 0.24 0.45 853533 26152
ZrMP-8 10.09 1.99 0.36 145 345 0.17 0.38 853533 25738
ZrMP-9 10.08 2.00 0.35 165 365 0.19 0.40 853526 24234
Zr (КТC-110), porosity 8.7 %, coating in the tensile zone
ZrMT-10 10.08 1.96 0.35 145 345 0.19 0.43 743398 10258
ZrMT-11 10.08 1.94 0.33 155 355 0.21 0.46 720164 10765
ZrMT-12 10.12 1.95 0.37 120 320 0.18 0.42 743393 11177
Zr (КТC-110), porosity 20.3 %, coating in the compression zone
ZrLP-13 10.04 1.97 0.36 115 315 0.14 0.37 768177 13382
ZrLP-14 10.11 2.00 0.35 185 385 0.20 0.42 794662 11053
ZrLP-15 10.04 2.00 0.36 135 335 0.17 0.40 794669 11776
Zr (КТC-110), porosity 20.3 %, coating in the tensile zone
ZrLT-16 10.09 1.95 0.35 170 370 0.24 0.49 720160 7426
ZrLT-17 10.11 1.95 0.37 100 300 0.13 0.38 720166 6610
ZrLT-18 10.10 1.98 0.35 280 480 0.37 0.61 743394 5198
Note: The bending stiffness of the sample was determined by Eq. 12. The distance between the supports in all
cases was l = 35 mm. The elasticity modulus of the coating was determined by Eq. 10.

The elasticity modulus of coatings from each of the studied materials with different contents of bulk
porosity was determined as the arithmetic mean value for three tested samples (Table 7).

Table 7
Arithmetic mean values of the elastic moduli of coatings made the alloys of grades VT1-00 and KTC-110 in the
zone of tension and compression depending on porosity.

Ті alloy grade VТ1-00 Zr alloy grade КТC-110

Porosit Modulus of elasticity of the Porosity Modulus of elasticity of the
EcT EcT
y (P), % coating in zone (P), % coating in zone
tension compression EcP , tension compression EcP ,
T P % T P %
E E E E
( c ), МPа ( c ), МPа ( c ), МPа ( c ), МPа
6.5 20237 47873 42.3 2.8 13413 34921 38.4
13.7 16452 36503 45.1 8.7 10733 25375 42.3
25.0 12770 19523 65.4 20.3 6411 12070 53.1

4. Discussion
Analysis of (Table 7) shows that for both materials Ti (VT1-00) and Zr (KTC-110), the modulus of
elasticity of the coating in the tension zone is significantly less than the corresponding value in the
compression zone at the same porosity. It should also be noted that with an increase in porosity, the
difference between the elastic modulus in the tension and compression zones decreases. Thus, with porosity
of 2.8%, the elastic modulus of the coating of Zr (KTC-110) in the tension zone is only 38.4% of the

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and zirconium grade KTC-110 on their porosity

corresponding characteristic of the same coating in the compression zone, and with porosity of 25% for a
coating of Ti (VT1-00) this ratio is 65.4%.
It is known [22] that the modulus of elasticity of samples of pure titanium made by powder sintering
with porosity of 28.6% is 37.700 MPa. Therefore, since the maximum elastic modulus Ti (VT1-00) of the
coating with porosity of 25.0% is 21777 MPa (Table 6, sample ТіLP-13), we can conclude that with an
increase in porosity, the modulus of elasticity of microplasma coatings decreases more intensively of
coatings made by powder sintering. The functional relationship between bulk porosity and modulus of
elasticity was established by constructing linear regression curves using the least squares method (Fig. 7).

а) b)

c) d)

Fig. 7. Graphs of dependence of the elasticity modulus of the coating on porosity: a) - for Ti (VT1-00) in the
tension zone; b) - for Ti (VT1-00) in the compression zone; c) for Zr (KTC-110) in the tension zone; d) for Zr
(KTC-110) in the compression zone.

The established regression coefficients make it possible to determine the elasticity moduli of
coatings depending on porosity using the equations:

– for Ti grade VТ1-00 in the tension zone

(13)
Ec = 22460 − 397  P ;
– for Ti grade VТ1-00 in the compression zone
(14)
Ec = 57680 − 1530  P ;
– for Zr grade КТC-110 in the tension zone

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and zirconium grade KTC-110 on their porosity

(15)
Ec = 14390 − 396  P ;
– for Zr grade КТC-110 in the compression zone
(16)
Ec = 37730 − 1284  P ,
where P – porosity of the coating, %.

5. Conclusions

The maximum deviation of the calculated value of the elastic modulus from the experimental value
for Eq. 13 is less than 3.5%, for Eq. 14 - less than 0.6%, for Eq. 15 - less than 2% and for Eq. 16 - close to
4.7%.
New experimental-theoretical technique has been developed that makes it possible to determine the
modulus of elasticity of the coating in bending without separating it from the substrate. Mathematical
equations have been obtained to determine the elasticity modulus of the coating in explicit form through
the geometric dimensions of the coating and substrate, the elasticity modulus of the substrate, and the
experimentally determined bending stiffness of the entire structure with a correlation of the calculated value
of the elasticity modulus from experimental value not exceeding 5%.
Functional relationship has been established between the modulus of elasticity and the porosity of
coatings made of titanium grade VT1-00 and zirconium grade KTC-110 for cases when they are in the
tension zone (Ti- 𝐸𝑐 = 22460 − 397 ⋅ 𝑃; Zr- 𝐸𝑐 = 14390 − 396 ⋅ 𝑃) and in compression zone (Ti-𝐸𝑐 =
57680 − 1530 ⋅ 𝑃 ; Zr-𝐸𝑐 = 37730 − 1284 ⋅ 𝑃 ).

Acknowledgements

The work was supported by the National Academy of Science of Ukraine under Grant number
0121U112006.

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