, Volume 22, Issue 2-3, pp 90-95
Date: 13 Nov 2012

In Situ Synthesis of FeAl Dense Coatings by Very Low Pressure Reactive Plasma Spraying

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With the purpose of elaborating high-quality FeAl coatings, a so-called very low pressure reactive plasma spray technique that combines very low pressure plasma spray and self-propagation high-temperature synthesis processes was used in the present study. A dense and homogeneous FeAl coating was thus successfully in situ synthesized by reactive plasma spraying of an Al/Fe2O3 composite powder under 1 mbar. The phase composition and microstructural features of the coating were characterized by XRD and SEM. Results indicated that the B2 ordered FeAl phase was synthesized, and the coating featured a dense and defect-free microstructure. The fracture mechanism of the coating remains mainly a brittle failure but the appearance of some dimples in local zones suggested some unexpected toughness.

This article is an invited paper selected from presentations at the 2012 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray 2012: Proceedings of the International Thermal Spray Conference, Air, Land, Water, and the Human Body: Thermal Spray Science and Applications, Houston, Texas, USA, May 21-24, 2012, Basil R. Marple, Arvind Agarwal, Laura Filofteia-Toma, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and André McDonald, Ed., ASM International, Materials Park, OH, 2012.