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Research Article

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

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  • Received: 1 July 2020Revised: 14 August 2020Accepted: 25 August 2020Available online: 27 August 2020
  • The present study explores the fabrication of Fe-based amorphous coating by air plasma spraying and its dependency on the coating parameters (plasma power, primary gas flow rate, stand-off distance and powder feed rate). XRD of the coatings deposited at optimized spray parameters showed the presence of amorphous-crystalline phase. Coatings deposited at lower plasma power and moderate gas flow rate exhibited better density, hardness and wear resistance. All coatings demonstrated equally good resistance against corrosive environment (NaCl). Mechanical, wear and tribological studies indicate that a single process parameter optimization cannot provide good coating performance but instead, all process parameters are having their unique role in defining better properties to 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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Process-structure-property relationship for plasma sprayed iron based amorphous-crystalline composite coatings

  • Corresponding author:

    Anup Kumar Keshri    E-mail: anup@iitp.ac.in

  • 1. R&D, Tata Steel, Jamshedpur 831001, Jharkhand, India
  • 2. Plasma Spray Coating Laboratory, Metallurgical and Materials Engineering, Indian Institute of Technology Patna, Bihta 801106, India

Abstract: The present study explores the fabrication of Fe-based amorphous coating by air plasma spraying and its dependency on the coating parameters (plasma power, primary gas flow rate, stand-off distance and powder feed rate). XRD of the coatings deposited at optimized spray parameters showed the presence of amorphous-crystalline phase. Coatings deposited at lower plasma power and moderate gas flow rate exhibited better density, hardness and wear resistance. All coatings demonstrated equally good resistance against corrosive environment (NaCl). Mechanical, wear and tribological studies indicate that a single process parameter optimization cannot provide good coating performance but instead, all process parameters are having their unique role in defining better properties to 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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