Skip to main content
SpringerLink
Log in

Comparative Study on Wear and Corrosion Behavior of Plasma Sprayed Fe73Cr2Si11B11C3 and Fe63Cr9P5B16C7 Metallic Glass Composite Coatings

  • Peer Reviewed
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

In the present study, Fe-based metallic glass composite coatings were synthesized by using two different low-Cr and inexpensive alloying elements containing compositions of Fe73Cr2Si11B11C3, at. % (P1) and Fe63Cr9P5B16C7, at. % (P2) to investigate their wear and corrosion properties. The coatings were synthesized under optimum spraying parameters via atmospheric plasma spraying (APS), and microstructural characterization showed that the coatings were dense (porosity < 5%) and primarily consisted of amorphous phase (amorphicity level > 84%). Interestingly, corrosion resistance of the P1 powder-based coating was comparable to high-Cr containing plasma-sprayed stainless steel (SS316L) coating despite very low Cr content, which is ascribed to the higher level of amorphicity. The P2-based coating exhibited superior corrosion resistance, attributed to a better combination of lower porosity (~3.3%), the presence of amorphous phase and formation of higher amount of protective α-CrOOH and Fe2−xCrxO3. Both the coatings exhibited higher wear resistance compared to the stainless steel coating. Nonetheless, P2-based coating displayed better anti-wear behavior, which was ascribed to its denser microstructure and presence of relatively higher content of hard Fe-based intermetallics. P2-based coating displayed higher value of wear property parameter (H/Er, 0.073), lower specific wear rate (6.1 × 10-6 mm3/Nm) and lower coefficient of friction (0.13), signifying excellent wear resistance.

Graphical Abstract

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. C.A.C. Souza, D.V. Ribeiro, and C.S. Kiminami, Corrosion Resistance of Fe-Cr-Based Amorphous Alloys: An Overview, J. Non. Cryst. Solids, 2016, 442, p 56–66.

    Article  CAS  Google Scholar 

  2. L. Liu and C. Zhang, Fe-Based Amorphous Coatings: Structures and Properties, Thin Solid Films, 2014, 561, p 70–86.

    Article  CAS  Google Scholar 

  3. B. Huang, C. Zhang, G. Zhang, and H. Liao, Wear and Corrosion Resistant Performance of Thermal-Sprayed Fe-Based Amorphous Coatings: A Review, Surf. Coat. Technol., 2019, 377, p 124896.

    Article  CAS  Google Scholar 

  4. G.Y. Koga, A.M.J. Junior, V. Roche, R.P. Nogueira, R. Schulz, S. Savoie, A.K. Melle, C. Loable, C. Bolfarini, C.S. Kiminami, and W.J. Botta, Production and Corrosion Resistance of Thermally Sprayed Fe-Based Amorphous Coatings from Mechanically Milled Feedstock Powders, Metall. Mater. Trans. A Phys. Metall. Mater. Sci., 2018, 49(10), p 4860–4870.

    Article  CAS  Google Scholar 

  5. X.Q. Liu, Y.G. Zheng, X.C. Chang, W.L. Hou, J.Q. Wang, Z. Tang, and A. Burgess, Microstructure and Properties of Fe-Based Amorphous Metallic Coating Produced by High Velocity Axial Plasma Spraying, J. Alloys Compd., 2009, 484(1–2), p 300–307.

    Article  CAS  Google Scholar 

  6. Z. Zhou, L. Wang, F.C. Wang, H.F. Zhang, Y.B. Liu, and S.H. Xu, Formation and Corrosion Behavior of Fe-Based Amorphous Metallic Coatings by HVOF Thermal Spraying, Surf. Coat. Technol., 2009, 204(5), p 563–570.

    Article  CAS  Google Scholar 

  7. R.Q. Guo, C. Zhang, Y. Yang, Y. Peng, and L. Liu, Corrosion and Wear Resistance of a Fe-Based Amorphous Coating in Underground Environment, Intermetallics, 2012, 30, p 94–99.

    Article  CAS  Google Scholar 

  8. W. Wang, C. Zhang, Z.W. Zhang, Y.C. Li, M. Yasir, H.T. Wang, and L. Liu, Toughening Fe-Based Amorphous Coatings by Reinforcement of Amorphous Carbon, Sci. Rep., 2017, 7(1), p 1–10.

    CAS  Google Scholar 

  9. W. Guo, Y. Wu, J. Zhang, S. Hong, G. Li, G. Ying, J. Guo, and Y. Qin, Fabrication and Characterization of Thermal-Sprayed Fe-Based Amorphous/Nanocrystalline Composite Coatings: An Overview, J. Therm. Spray Technol., 2014, 23(7), p 1157–1180.

    Article  CAS  Google Scholar 

  10. A. Concustell, J. Henao, S. Dosta, N. Cinca, I.G. Cano, and J.M. Guilemany, On the Formation of Metallic Glass Coatings by Means of Cold Gas Spray Technology, J. Alloys Compd., 2015, 651, p 764–772.

    Article  CAS  Google Scholar 

  11. V. Varadaraajan, R.K. Guduru, and P.S. Mohanty, Synthesis and Microstructural Evolution of Amorphous/Nanocrystalline Steel Coatings by Different Thermal-Spray Processes, J. Therm. Spray Technol., 2013, 22(4), p 452–462.

    Article  CAS  Google Scholar 

  12. H. Zhang, Y. Xie, L. Huang, S. Huang, X. Zheng, and G. Chen, Effect of Feedstock Particle Sizes on Wear Resistance of Plasma Sprayed Fe-Based Amorphous Coatings, Surf. Coat. Technol., 2014, 258, p 495–502.

    Article  CAS  Google Scholar 

  13. Y. An, G. Hou, J. Chen, X. Zhao, G. Liu, H. Zhou, and J. Chen, Microstructure and Tribological Properties of Iron-Based Metallic Glass Coatings Prepared by Atmospheric Plasma Spraying, Vacuum, 2014, 107, p 132–140.

    Article  CAS  Google Scholar 

  14. Y.C. Li, C. Zhang, W. Xing, S.F. Guo, and L. Liu, Design of Fe-Based Bulk Metallic Glasses with Improved Wear Resistance, ACS Appl. Mater. Interfaces, 2018, 10(49), p 43144–43155.

    Article  CAS  Google Scholar 

  15. C. Zhang, L. Liu, K.C. Chan, Q. Chen, and C.Y. Tang, Wear Behavior of HVOF-Sprayed Fe-Based Amorphous Coatings, Intermetallics, 2012, 29, p 80–85.

    Article  CAS  Google Scholar 

  16. A. Kumar, S.K. Nayak, K. Sarkar, A. Banerjee, K. Mondal, and T. Laha, Investigation of Nano- and Micro-Scale Structural Evolution and Resulting Corrosion Resistance in Plasma Sprayed Fe-Based (Fe-Cr-B-C-P) Amorphous Coatings, Surf. Coat. Technol., 2020, 397, p 126058.

    Article  CAS  Google Scholar 

  17. G. Liu, Y. An, Z. Guo, J. Chen, G. Hou, and J. Chen, Structure and Corrosion Behavior of Iron-Based Metallic Glass Coatings Prepared by LPPS, Appl. Surf. Sci., 2012, 258(14), p 5380–5386.

    Article  CAS  Google Scholar 

  18. G.Y. Koga, T. Ferreira, Y. Guo, D.D. Coimbrão, A.M. Jorge, C.S. Kiminami, C. Bolfarini, and W.J. Botta, Challenges in Optimizing the Resistance to Corrosion and Wear of Amorphous Fe-Cr-Nb-B Alloy Containing Crystalline Phases, J. Non. Cryst. Solids, 2021, 555, p 120537.

    Article  CAS  Google Scholar 

  19. R. Moreton and J.K. Lancaster, The Friction and Wear Behaviour of Various Metallic Glasses, J. Mater. Sci. Lett., 1985, 4(2), p 133–137.

    Article  CAS  Google Scholar 

  20. A. Kumar, S.K. Nayak, P. Bijalwan, M. Dutta, A. Banerjee, and T. Laha, Optimization of Mechanical and Corrosion Properties of Plasma Sprayed Low-Chromium Containing Fe-Based Amorphous/Nanocrystalline Composite Coating, Surf. Coat. Technol., 2019, 370, p 255–268.

    Article  CAS  Google Scholar 

  21. C. Zhang, K.C. Chan, Y. Wu, and L. Liu, Pitting Initiation in Fe-Based Amorphous Coatings, Acta Mater., 2012, 60(10), p 4152–4159.

    Article  CAS  Google Scholar 

  22. W.H. Wang, Roles of Minor Additions in Formation and Properties of Bulk Metallic Glasses, Prog. Mater. Sci., 2007, 52(4), p 540–596.

    Article  CAS  Google Scholar 

  23. M. Naka, Effect of Metalloidal Elements on the Microhardness of Iron-Base Glasses, J. Appl. Phys., 1980, 51(11), p 6006–6009.

    Article  CAS  Google Scholar 

  24. M. Madinehei, P. Bruna, M.J. Duarte, E. Pineda, J. Klemm, and F.U. Renner, Glass-Formation and Corrosion Properties of Fe-Cr-Mo-C-B Glassy Ribbons with Low Cr Content, J. Alloys Compd., 2014, 615(S1), p S128–S131.

    Article  CAS  Google Scholar 

  25. C. Suryanarayana and A. Inoue, Iron-Based Bulk Metallic Glasses, Int. Mater. Rev., 2013, 58(3), p 131–166.

    Article  CAS  Google Scholar 

  26. J. Fornell, S. González, E. Rossinyol, S. Suriñach, M.D. Baró, D.V. Louzguine-Luzgin, J.H. Perepezko, J. Sort ,and A. Inoue, Enhanced Mechanical Properties Due to Structural Changes Induced by Devitrification in Fe-Co-B-Si-Nb Bulk Metallic Glass, Acta Mater., 2010, 58(19), p 6256–6266.

    Article  CAS  Google Scholar 

  27. H.X. Li, Z.C. Lu, S.L. Wang, Y. Wu, and Z.P. Lu, Fe-Based Bulk Metallic Glasses: Glass Formation, Fabrication, Properties and Applications, Prog. Mater. Sci., 2019, 103, p 235–318.

    Article  CAS  Google Scholar 

  28. J. Henao, A. Concustell, I.G. Cano, N. Cinca, S. Dosta, and J.M. Guilemany, Influence of Cold Gas Spray Process Conditions on the Microstructure of Fe-Based Amorphous Coatings, J. Alloys Compd., 2015, 622, p 995–999.

    Article  CAS  Google Scholar 

  29. S.K. Nayak, A. Kumar, A. Pathak, A. Banerjee, and T. Laha, Multi-Scale Mechanical Properties of Fe-Based Amorphous/Nanocrystalline Composite Coating Synthesized by HVOF Spraying, J. Alloys Compd., 2020, 825, p 154120.

    Article  CAS  Google Scholar 

  30. A. Kumar, R. Kumar, P. Bijalwan, M. Dutta, A. Banerjee, and T. Laha, Fe-Based Amorphous/Nanocrystalline Composite Coating by Plasma Spraying: Effect of Heat Input on Morphology, Phase Evolution and Mechanical Properties, J. Alloys Compd., 2019, 771, p 827–837.

    Article  CAS  Google Scholar 

  31. C. Chattopadhyay, K.S.N.S. Idury, J. Bhatt, K. Mondal, and B.S. Murty, Critical Evaluation of Glass Forming Ability Criteria, Mater. Sci. Technol. (United Kingdom), 2016, 32(4), p 380–400.

    Article  CAS  Google Scholar 

  32. B.R. Rao, M. Srinivas, A.K. Shah, A.S. Gandhi, and B.S. Murty, A New Thermodynamic Parameter to Predict Glass Forming Ability in Iron Based Multi-Component Systems Containing Zirconium, Intermetallics, 2013, 35, p 73–81.

    Article  CAS  Google Scholar 

  33. A. Leyland and A. Matthews, On the Significance of the H/E Ratio in Wear Control: A Nanocomposite Coating Approach to Optimised Tribological Behaviour, Wear, 2000, 246(1–2), p 1–11.

    Article  CAS  Google Scholar 

  34. N.K. Mukhopadhyay, C. Dong, Q. Jianbing, and V.S. Sarma, Nanoindentation Studies on Ti-Zr-Ni Bulk Quasicrystalline Intermetallics, Philos. Mag., 2007, 87(18–21), p 3109–3115.

    Article  CAS  Google Scholar 

  35. K. Balani, S.P. Harimkar, A. Keshri, Y. Chen, N.B. Dahotre, and A. Agarwal, Multiscale Wear of Plasma-Sprayed Carbon-Nanotube-Reinforced Aluminum Oxide Nanocomposite Coating, Acta Mater., 2008, 56(20), p 5984–5994.

    Article  CAS  Google Scholar 

  36. A.A. Burkov and P.G. Chigrin, Effect of Tungsten, Molybdenum, Nickel and Cobalt on the Corrosion and Wear Performance of Fe-Based Metallic Glass Coatings, Surf. Coat. Technol., 2018, 351, p 68–77.

    Article  CAS  Google Scholar 

  37. G.S. Ham, K.W. Kim, G.S. Cho, C.P. Kim, and K.A. Lee, Fabrication, Microstructure and Wear Properties of Novel Fe-Mo-Cr-C-B Metallic Glass Coating Layers Manufactured by Various Thermal Spray Processes, Mater. Des., 2020, 195, p 109043.

    Article  CAS  Google Scholar 

  38. C. Zhang, Z. Chu, F. Wei, W. Qin, Y. Yang, Y. Dong, D. Huang, and L. Wang, Optimizing Process and the Properties of the Sprayed Fe-Based Metallic Glassy Coating by Plasma Spraying, Surf. Coat. Technol., 2017, 319, p 1–5.

    Article  CAS  Google Scholar 

  39. C.P. Jiang, Y.Z. Xing, F.Y. Zhang, and J.M. Hao, Microstructure and Corrosion Resistance of Fe/Mo Composite Amorphous Coatings Prepared by Air Plasma Spraying, Int. J. Miner. Metall. Mater., 2012, 19(7), p 657–662.

    Article  CAS  Google Scholar 

  40. S.K. Nayak, A. Kumar, K. Sarkar, A. Pathak, A. Banerjee, and T. Laha, A Study on the Corrosion Inhibition of Fe-Based Amorphous/Nanocrystalline Coating Synthesized by High-Velocity Oxy-Fuel Spraying in an Extreme Environment, J. Therm. Spray Technol., 2019, 28(7), p 1433–1447.

    Article  CAS  Google Scholar 

  41. S. Choudhary, A. Garg, and K. Mondal, Relation Between Open Circuit Potential and Polarization Resistance with Rust and Corrosion Monitoring of Mild Steel, J. Mater. Eng. Perform., 2016, 25(7), p 2969–2976.

    Article  CAS  Google Scholar 

  42. R. Balasubramaniam, A.V.R. Kumar, and P. Dillmann, Characterization of Rust on Ancient Indian Iron, Curr. Sci., 2003, 85(11), p 1546–1555.

    CAS  Google Scholar 

  43. K.F. McCarty and D.R. Boehme, A Raman Study of the Systems Fe3-XCrxO4 and Fe2-XCrxO3, J. Solid State Chem., 1989, 79(1), p 19–27.

    Article  CAS  Google Scholar 

  44. J.E. Maslar, W.S. Hurst, J.J. Bowers, and J.H. Hendricks, In Situ Raman Spectroscopic Investigation of Stainless Steel Hydrothermal Corrosion, Corrosion, 2002, 58(9), p 739–747.

    Article  CAS  Google Scholar 

  45. P. Bijalwan, C. Singh, A. Kumar, K. Sarkar, N. Rani, T. Laha, A. Banerjee, and K. Mondal, Corrosion behaviour of plasma sprayed Fe based metallic glass (Fe73Cr2Si11B11C3 (at%) coatings in 3.5% NaCl solution, J. Non. Cryst. Solids, 2021, 567, p 120913.

    Article  CAS  Google Scholar 

Download references

Acknowledgment

The author, T. Laha thankfully acknowledges Science and Engineering Research Board, Department of Science and Technology, Govt. of India (CRG/2020/000738) and Defence Research and Development Organisation, Govt. of India (ERIP/ER/202101002/M/01/1783) for financial support.

Author information

Authors and Affiliations

  1. Department of Metallurgical and Materials Engineering, Indian Institute of Technology Kharagpur, Kharagpur, WB, 721302, India

    Anil Kumar, Sapan K. Nayak & Tapas Laha

Authors
  1. Anil Kumar
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Sapan K. Nayak
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Tapas Laha
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Anil Kumar or Tapas Laha.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

This article is part of a special topical focus in the Journal of Thermal Spray Technology on High Entropy Alloy and Bulk Metallic Glass Coatings. The issue was organized by Dr. Andrew S.M. Ang, Swinburne University of Technology; Prof. B.S. Murty, Indian Institute of Technology Hyderabad; Distinguished Prof. Jien-Wei Yeh, National Tsing Hua University; Prof. Paul Munroe, University of New South Wales; Distinguished Prof. Christopher C. Berndt, Swinburne University of Technology. The issue organizers were mentored by Emeritus Prof. S. Ranganathan, Indian Institute of Sciences.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Kumar, A., Nayak, S.K. & Laha, T. Comparative Study on Wear and Corrosion Behavior of Plasma Sprayed Fe73Cr2Si11B11C3 and Fe63Cr9P5B16C7 Metallic Glass Composite Coatings. J Therm Spray Tech 31, 1302–1316 (2022). https://doi.org/10.1007/s11666-021-01280-1

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11666-021-01280-1

Keywords

Search

Navigation