Influence of processing conditions on the microstructure and sliding wear of a promising Fe-based coating deposited by HVAF

Thermal spray is a versatile and cost-effective process to deposit wear corrosion resistant coatings. In this work, relatively new ‘Fe-based’ chemistry comprising boride carbides, explored as ‘greener’ alternative the expensive carcinogenic Co-based coatings mitigate wear. The emergent thermal of high-velocity air-fuel (HVAF) spraying was chosen Fe-based coatings, with oxy-fuel (HVOF) also being employed solely for purpose preliminary comparison. Detailed characterization HVOF HVAF sprayed carried out. Microstructure, porosity, hardness phase analysis results demonstrate influence processing conditions, where specific conditions yielded minimal undeformed particulates content, high hardness, low porosity feedstock retention. Differences in microstructural features as-deposited relation their are discussed detail. were subjected ball-on-disc tribometry tests at different load friction performance evaluated. coefficient investigated concurred respective features. Post-mortem worn coating surface, mating alumina ball surface debris performed using SEM/EDS understand associated mechanisms material transfer. This work provides insights on identifying appropriate achieve acceptable phases improved performance.