Wear Properties of Iron-Based Alloy Coatings Prepared by Plasma Transfer Arc Cladding

Plasma transfer arc cladding technology has been widely utilized in surface engineering, repairing and remanufacturing. In the present work, multiple cladded thick claddings were prepared on compacted graphite cast iron (CGI) substrates with iron-based powders through plasma transfer arc cladding technology using different plasma arc currents to improve the surface wear resistance. The coatings’ phase and microstructure were analysed through XRD, SEM and EDS. The coatings’ microhardness and wear resistance were characterized. There were pearlite, graphite, austenite and secondary carbides in the iron-based alloy coatings. Due to the heat influence during the multiple cladding process, a spheroidal graphite transition zone appeared between the substrate and the coating. The microhardness of the claddings varied from 363 to 402 HV as the plasma arc current was changed from 45 to 60 A. With the increase of plasma arc current, the cladding’s microhardness increased. The iron-based coating’s minimum friction coefficient and wear mass loss were about 0.48 and 4.2 mg, respectively, when the plasma arc current was 60 A, which are lower values than those of the compacted graphite iron substrate with the friction coefficient and wear mass loss of 0.55 and 8.2 mg. Compared with the substrate, the iron-based alloy claddings achieved the effect of reducing friction and wear resistance simultaneously, which resulted from the self-lubricating effect of graphite and high wear-resistance of carbides in the claddings. The iron-based coatings had a similar abrasive wear mechanism to the CGI, which should be helpful to repair or remanufacture CGI workpieces.