journal article·2022-03-11Open access

Influence of Heat Treatment on the Microstructure and Wear Properties of Arc-Sprayed FeCrAl/Al Coating

Joseph Ndumia, Min Kang, Jinran Lin, Jitao Liu, Hao Li

Coatings· Volume 12· Issue 3

Abstract

Intermetallic compounds formed during heat treatment of alloy coatings affect the coating structure and properties. In order to determine the phase changes and coating performance, FeCrAl (Fe Bal., Cr 26 wt.%, Al 6 wt.%) and Al (99.9 wt.%) coating was sprayed onto low carbon steel substrates and subsequently heat-treated at different temperatures. The effects of heat treatment on the microstructure, phase composition, tensile bonding strength, microhardness, and wear properties of the coatings were analyzed. The as-sprayed coating had a dense, layered structure with an average porosity of 3.6%. The microhardness of the as-sprayed coating was comprised of hard FeCrAl splats and ductile Al splats with an average microhardness value of 494 HV0.1. The coating at 300 °C had the highest tensile strength of 37.5 MPa. At 500 °C, FeAl intermetallic compounds formed at the phase boundaries due to the diffusion of elements. The coating microhardness and wear resistance were affected by the uniform coating structure and the precipitation of FeAl intermetallic compounds. Compared with the annealed coatings, the as-sprayed coating had the lowest wear rate.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: High-Temperature Coating Behaviors · Intermetallics and Advanced Alloy Properties · Metal Alloys Wear and Properties

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

Affiliations

College of Engineering, Nanjing Agricultural University, Nanjing 210031, China

Funding

Jiangsu Provincial Key Research and Development Plan

References (51)

Show source-provided references
1. Boronenkov, V., and Korobov, Y. (2016). Physical and Chemical Regularities, Springer.
2. Tribological and Microstructural Properties of Carbon Steel Coatings Fabricated by Wire Arc Spray10.1007/s12540-019-00354-8 ↗
3. Thermal plasma technology: The prospective future in material processing10.1016/j.jclepro.2016.10.154 ↗
4. FeAl and FeCrAl as Alternative Coatings for NiAl
5. Ndumia, J.N., Kang, M., Gbenontin, B.V., Lin, J., and Nyambura, S.M. (2021). A Review on the Wear, Corrosion and High-Temperature Resistant Properties of Wire Arc-Sprayed Fe-Based Coatings. Nanomaterials, 11.10.3390/nano11102527 ↗
6. Advanced intermetallic iron aluminide coatings for high temperature applications10.1016/j.pmatsci.2020.100769 ↗
7. Performance and microstructure analysis of 99.5% aluminium coating by thermal arc spray technique10.1016/j.proeng.2013.12.221 ↗
8. Pore blocking characteristics of corrosion products formed on Aluminum coating produced by arc thermal metal spray process in 3.5 wt.% NaCl solution10.1016/j.conbuildmat.2016.03.135 ↗
9. Zhao, J.H., Wang, L., and Shang, Z.H. (2015). Materials Science Forum, Trans Tech Publications Ltd.
10. Structure and sliding wear behavior of 321 stainless steel/Al composite coating deposited by high velocity arc spraying technique10.1016/S1003-6326(08)60105-3 ↗
11. Bratean, L. (2014, January 7–9). Thermal spraying arc process with two dissimilar wires–quality tests. Proceedings of the 6th International Conference Edu World 2014 Education Facing Contemporary World Issues, Pitesti, Romania.
12. Pseudo-alloys for spray metal tooling: Pseudo-alloys have enhanced the durability of metal-faced composite tooling for metal forming and plastics molding
13. Research on anticorrosion characteristics of AlZn pseudo-alloy obtained by metal-arc process
14. Electrode phenomena investigation of wire arc spraying for preparation of Ti-Al intermetallic compounds10.1016/S0040-6090(02)00019-6 ↗
15. Post-heat treatment of arc-sprayed coating prepared by the wires combination of Mg-cathode and Al-anode to form protective intermetallic layers10.1016/j.apsusc.2010.10.123 ↗
16. Heat treatment induced intermetallic phase transition of arc-sprayed coating prepared by the wires combination of aluminum-cathode and steel-anode10.1016/j.apsusc.2009.05.142 ↗
17. Annealing behavior of aluminum coating prepared by arc spraying on P355NL1 steel10.1016/j.surfcoat.2017.09.073 ↗
18. Wear-resistant intermetallic arc spray coatings
19. Ndiithi, N.J., Kang, M., Zhu, J., Lin, J., Nyambura, S.M., Liu, Y., and Huang, F. (2019). Microstructural and corrosion behavior of high velocity arc sprayed FeCrAl/Al composite coating on Q235 steel substrate. Coatings, 9.10.3390/coatings9090542 ↗
20. Quantitative characteristics of FeCrAl films deposited by arc and high-velocity arc spraying10.1016/S1044-5803(01)00108-5 ↗
21. Control of intermetallic compound layers at interface between steel and aluminum by diffusion-treatment10.1016/S0921-5093(02)00053-9 ↗
22. (2017). Standard Test Method for Adhesion or Cohesion Strength of Thermal Spray Coatings (Standard No. ASTM C633-13).
23. (2010). Standard Test Method for Linearly Reciprocating Ball-on-Flat Sliding Wear (Standard No. ASTM G133-05).
24. Oxidation during electric arc spray forming of steel10.1016/j.jmatprotec.2006.03.176 ↗
25. Wear mechanism of iron-based alloy coating by arc spraying10.1016/S1006-706X(16)30128-5 ↗
26. Study of Porosity on Titania Slag Obtained by Conventional Sintering and Thermal Plasma Process
27. Annealing effect on the intermetallic compound formation of cold sprayed Fe/Al composite coating10.1007/s11666-011-9722-1 ↗
28. Influences of Structural Relaxation and Crystallization on Dry-Sliding Tribological Behavior of Fe-Based Amorphous Coating10.1007/s11249-021-01437-7 ↗
29. Influence of FeCrAl content on microstructure and bonding strength of plasma-sprayed FeCrAl/Al2O3 coatings10.1007/s11666-015-0363-7 ↗
30. Evaluation of adhesion/cohesion bond strength of the thick plasma spray coatings by scratch testing on coatings cross-sections10.1016/j.triboint.2011.04.002 ↗
31. Influence of Substrate Temperature on Structure and Adhesion Strength of Fe–Cr–P–C Amorphous Coating Films Produced by Thermal Spraying Technique10.2320/matertrans.M2011261 ↗
32. Influence of Substrate Temperature on the Structure and Cohesive/Adhesive Strength of Fe-Co-Si-B-Nb Metallic Glass Coating Films Produced by Thermal Spraying10.2320/matertrans.M2012282 ↗
33. On the bonding strength in thermally sprayed Fe-based amorphous coatings10.1016/j.surfcoat.2012.12.018 ↗
34. Effect of Al content on high temperature erosion properties of arc-sprayed FeMnCrAl/Cr3C2 coatings10.1016/S1003-6326(09)60121-7 ↗
35. Oxidation control in arc-sprayed SS420 coating10.1080/02670844.2020.1840696 ↗
36. Oxidation in wire HVOF-sprayed steel10.1361/105996398770350765 ↗
37. Cold spraying of Fe/Al powder mixture: Coating characteristics and influence of heat treatment on the phase structure10.1016/j.apsusc.2008.07.127 ↗
38. Microstructural and kinetic aspects of the transformations induced in a FeAl alloy by ball-milling and thermal treatments10.1016/S1359-6454(97)00484-9 ↗
39. Effect of heat treatment on the microstructure and property of cold-sprayed nanostructured FeAl/Al2O3 intermetallic composite coating10.1016/j.vacuum.2008.03.094 ↗
40. Effects of heat treatment on tribological behavior of electroless Ni–B coating at elevated temperatures10.1142/S0218625X18500142 ↗
41. Han, Y., and Li, L. (2009). Advanced Tribology, Springer.
42. Frictional wear performance under oil-lubricated conditions and wear resistance mechanism of high-velocity arc-sprayed FeNiCrAl coating10.1016/j.surfcoat.2018.08.060 ↗
43. Mechanical and tribological properties of Zr-Al-Ni-Cu bulk metallic glasses10.1016/j.jallcom.2008.02.002 ↗
44. Adhesive strength and abrasive property of Fe based composite coating deposited by high velocity arc spraying10.1179/1432891714Z.000000000425 ↗
45. High corrosion and wear resistance of Al-based amorphous metallic coating synthesized by HVAF spraying10.1016/j.jallcom.2017.11.274 ↗
46. High velocity electric arc sprayed Fe-Al-Nb-B composite coating and its wear behavior10.1007/s40195-013-0017-z ↗
47. High Temperature Friction and Wear Performance of PVD Coatings under Press Hardening Contact Conditions10.1155/2019/4981246 ↗
48. Influence of heat treatment on microstructure and tribological properties of flame spraying Fe-Ni-Al alloy coating10.1007/s11771-018-3751-6 ↗
49. Microstructure and wear performance of arc-sprayed Al/316L stainless-steel composite coating10.1016/j.surfcoat.2019.06.006 ↗
50. Effect of the temperature on the friction and wear properties of bulk amorphous alloy10.1142/S0218625X1450067X ↗
51. Zhu, W., Kang, M., Ndumia, J.N., Lin, J., Huang, F., and Zhang, Y. (2022). Microstructure and Wear Properties of TiB2 Reinforced Fe-Based Composite Coating. J. Mater. Eng. Perform., 1–12.10.1007/s11665-022-06612-y ↗