Microstructures and wear resistance of iron-based protective coatings by Supersonic Arc Spraying

The characteristics in microstructure, surface morphology, chemical composition, hardness and wear resistance of the three protective iron-based compound coatings prepared by Supersonic Arc Spraying (HVAS), were investigated by X-ray diffraction (XRD), Field emission scanning electron microscope (FESEM), Energy disperse spectroscopy (EDS) and Rockwell apparatus in this paper. It is indicated that the three coatings are typical layer and compact structures. The coatings are composed of Fe(s.s) phase and various kinds of ferric oxides, chrome carbides and/ or intermetallic phase distributing along the interface of lamellar layers. More Cr and Ti, Al elements in the cored wires can degrease the diameter and alternate the morphologies of the holes in the coating, resulting from the formation of oxides, carbides and intermetallic phase during depositing the coating. The results indicate the SXTiAlC coating shows the most excellent wear performance among the three coatings. The wear behavior and mechanism are discussed.