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Process—structure—property relationship for plasma-sprayed iron-based amorphous/crystalline composite coatings

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Abstract

This study explores the fabrication of Fe-based amorphous/crystalline coating by air plasma spraying and its dependency on the coating parameters (plasma power, primary gas flow rate, powder feed rate, and stand-off distance). X-ray diffraction of the coatings deposited at optimized spray parameters showed the presence of amorphous/crystalline phase. Coatings deposited at a lower plasma power and highest gas flow rate exhibited better density, hardness, and wear resistance. All coatings demonstrated equally good resistance against the corrosive environment (3.5wt% NaCl solution). Mechanical, wear, and tribological studies indicated that a single process parameter optimization cannot provide good coating performance; instead, all process parameters have a unique role in defining better properties for the coating by controlling the in-flight particle temperature and velocity profile, followed by the cooling pattern of molten droplet before impingement on the substrate.

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Acknowledgements

The authors sincerely acknowledge the financial support provided by Tata Steel Limited, Jamshedpur, India. The authors also sincerely acknowledge the support from the Indian Institute of Technology Patna.

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Authors and Affiliations

  1. Research and Development Unit, Tata Steel, Jamshedpur, 831001, India

    Abhishek Pathak, Pavan Bijalwan, Monojit Dutta & Atanu Banerjee

  2. Plasma Spray Coating Laboratory, Metallurgical and Materials Engineering, Indian Institute of Technology Patna, Bihta, 801106, India

    Biswajyoti Mukherjee, Krishna Kant Pandey, Aminul Islam & Anup Kumar Keshri

Authors
  1. Abhishek Pathak
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  2. Biswajyoti Mukherjee
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  3. Krishna Kant Pandey
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  4. Aminul Islam
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  5. Pavan Bijalwan
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  6. Monojit Dutta
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  7. Atanu Banerjee
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  8. Anup Kumar Keshri
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Correspondence to Anup Kumar Keshri.

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Pathak, A., Mukherjee, B., Pandey, K.K. et al. Process—structure—property relationship for plasma-sprayed iron-based amorphous/crystalline composite coatings. Int J Miner Metall Mater 29, 144–152 (2022). https://doi.org/10.1007/s12613-020-2171-4

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  • DOI: https://doi.org/10.1007/s12613-020-2171-4

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