Highly Economical Fe-based Protective Coating System by Novel Material Design and Full Utilization of the Atomized Powder

摘要

In this study, a novel economical Ni- and Mo-free wear and corrosion resistant FeCrMn alloy was designed. Spray powders of this alloy were produced through gas atomization. The total atomized powder was fractioned to -90 +45μm, -45 +25μm, -25 +10μm and -10μm. These powders were characterized in terms of their size distributions and morphologies. Subsequently, they were sprayed by a three-cathode plasma generator TriplexPro-210. It was found that fine powders with fractions of -25 +10μm and -10μm showed a significantly higher affinity to oxidation than coarser ones. Nevertheless, dense coatings with low oxide contents could be realized using suitable parameters even with the finest powder. The results show that a full utilization of the atomized powder can be realized by three-cathode plasma spraying due to its wide parameter window. The average deposition efficiency is more than 70%. In this way, the atomized powder can be used very efficiently. This contributes additionally to the high economical potential of this coating system which exhibits higher wear resistance than conventional stainless steel coatings and significantly higher corrosion resistance compared to carbon steels as well as cast irons.