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Microstructure and Sliding Wear Behavior of Fe-Based Coatings Manufactured with HVOF and HVAF Thermal Spray Processes

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Abstract

The microstructure and micromechanical behavior of thermally sprayed Fe-based coatings manufactured with high-velocity oxygen fuel (HVOF) and high-velocity air fuel (HVAF) processes were investigated. Fe-Cr-Ni-Si-B-C and Fe-Cr-Ni-Mo-Si-B-C powders were used as the feedstock materials. The coatings showed a highly dense microstructure with near-zero oxidation. The microstructure of the feedstock powders was better retained when sprayed with HVAF process. Differential scanning calorimetry revealed two small exothermic peaks at about 600 °C for the HVOF-sprayed coatings, without any increase in weight in thermogravimetric analysis. It suggested the re-precipitation of carbides that were dissolved during spraying due to the higher particle temperature reported by spray diagnostics system during the HVOF process (≈1800 °C) compared to the HVAF one (≈1400 °C). Micro- and nano-indentations helped to show the difference in inter-lamellar cohesive strength and, in turn, in the particle deposition mechanism. Coatings sprayed with Fe-Cr-Ni-Mo-Si-B-C composition possessed higher sliding wear resistance than that of Fe-Cr-Ni-Si-B-C due to higher nano-hardness. More specifically, HVOF-sprayed Fe-Cr-Ni-Mo-Si-B-C coating showed the largest intra-lamellar hardness, the largest elasticity, and high quality of particle interfaces which resulted in lower sliding wear rate.

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Acknowledgments

The authors would like to thank Mr. Mikko Kylmälahti of Tampere University of Technology, Department of Materials Science, for spraying the coatings, M.Sc. Jarmo Laakso, of Tampere University of Technology, Department of Materials Science, for FESEM studies of worn surfaces, and Dr. Paola Miselli, of University of Modena and Reggio Emilia, Department of Engineering “Enzo Ferrari”, for performing the DTA/TG analyses. The study was supported by the Finnish National Graduate School (Concurrent Mechanical Engineering) and Tampere University of Technology.

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Authors and Affiliations

  1. Department of Materials Science, Tampere University of Technology, Tampere, Finland

    A. Milanti, V. Matikainen, H. Koivuluoto & P. Vuoristo

  2. Department of Engineering “Enzo Ferrari”, University of Modena and Reggio Emilia, Modena, Italy

    G. Bolelli & L. Lusvarghi

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  1. A. Milanti
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  2. V. Matikainen
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Correspondence to A. Milanti.

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Milanti, A., Matikainen, V., Bolelli, G. et al. Microstructure and Sliding Wear Behavior of Fe-Based Coatings Manufactured with HVOF and HVAF Thermal Spray Processes. J Therm Spray Tech 25, 1040–1055 (2016). https://doi.org/10.1007/s11666-016-0410-z

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  • DOI: https://doi.org/10.1007/s11666-016-0410-z

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