Preparation and properties of the Ni-Al/Fe-Al intermetallics composite coating produced by plasma cladding

Abstract

A novel approach to produce an intermetallic composite coating was put forward. The microstructure, microhardness, and dry-sliding wear behavior of the composite coating were investigated using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive spectrum (EDS) analysis, microhardness test, and ball-on-disc wear experiment. XRD results indicate that some new phases FeAl, Fe_0.23Ni_0.77Al, and Ni₃Al exit in the composite coating with the Al₂O₃ addition. SEM results show that the coating is bonded with carbon steel metallurgically and exhibits typical rapid directional solidification structures. The Cr₇C₃ carbide and intermetallic compounds co-reinforced composite coating has a high average hardness and exhibits an excellent wear resistance under dry-sliding wear test compared with the Cr₇C₃ carbide-reinforced composite coating. The formation mechanism of the intermetallic compounds was also investigated.

Keywords

composite coatings / plasma cladding / intermetallics / microhardness / wear resistance

References

[1] Kanenoa Y., Matsumotoa N., Tsuji b N., et al. Plasma-assisted surface hardening of dual two-phase intermetallic alloy composed of Ni3X type structures. Mater. Sci. Eng. A, 2009, 516, 84.

[2] Szczucka-Lasota B., Formanek B., Hernas A., et al. Oxidation models of the growth of corrosion products on the intermetallic coatings strengthened by a fine dispersive Al₂O₃. J. Mater. Process. Technol., 2005, 164–165, 935.

[3] Zhu X., Yao Z., Gu X., et al. Microstructure and corrosion resistance of Fe-Al intermetallic coating on 45 steel synthesized by double glow plasma surface alloying technology. Trans. Nonferrous Met. Soc. China, 2009, 19, 143.

[4] Chen Y., Wang H.M. High-temperature wear resistance of a laser clad TiC reinforced FeAl in situ composite coating. Surf. Coat. Technol., 2004, 179, 252.

[5] Liu J., Wang L., Huang J. PTA clad (Cr, Fe)₇C₃/γ-Fe in situ ceramal composite coating. J. Univ. Sci. Technol. Beijing, 2006, 13, 538.

[6] Li H., Liu B., Li H., et al. Study on Fe-based Coating Produced by Plasma surface metallurgy. Trans. Mater. Heat Treat., 2004, 25, 952.

[7] Balasubramanian V., Lakshminarayanan A.K., Varahamoorthy R., et al. Application of response surface methodolody to prediction of dilution in plasma transferred arc hardfacing of stainless steel on carbon steel. J. Iron Steel Res. Int., 2009, 16, 44.

[8] Skarvelis P., Papadimitriou G.D. Plasma transferred arc composite coatings with self lubricating properties, based on Fe and Ti sulfides: microstructure and tribological behavior. Surf. Coat. Technol., 2009, 203, 1384.

[9] Liu Y.F., Xia Z.Y., Han J.M., et al. Microstructure and wear behavior of (Cr,Fe)₇C₃ reinforced composite coating produced by plasma transferred arc weld-surfacing process. Surf. Coat. Technol., 2006, 201, 863.

[10] Zhang L., Sun D., Yu H. Characteristics of plasma cladding Fe-based alloy coatings with rare earth metal elements. Mater. Sci. Eng. A, 2007, 452–453, 619.

[11] Zhang L., Liu B., Yu H., et al. Rapidly solidified non-equilibrium microstructure and phase transformation of plasma cladding Fe-based alloy coating. Surf. Coat. Technol., 2007, 201, 5931.

[12] Zhang L., Sun D., Yu H., et al. Characteristics of Fe-based alloy coating produced by plasma cladding process. Mater. Sci. Eng. A, 2007, 457, 319.

[13] Xu B., Zhu Z., Ma S. Sliding wear behavior of Fe-Al and Fe-Al/WC coatings prepared by high velocity arc spraying. Wear, 2004, 257, 1089.

[14] Fröhlich M., Braun R., Leyens C. Oxidation resistant coatings in combination with thermal barrier coatings on γ-TiAl alloys for high temperature applications. Surf. Coat. Technol., 2006, 201, 3911.

[15] Costa M.Y.P., Venditti M.L.R., Voorwald H.J.C. WC-10%Co-4%Cr coating on the Ti-6Al-4V alloy fatigue strength. Mater. Sci. Eng. A, 2009, 507, 29.