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Effect of Microstructure and Phase Evolution on the Wear Behavior of Fe-Based Amorphous/Nanocrystalline Composite Coatings Synthesized by Plasma Spraying

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Abstract

In this work, Fe-10Cr-10Mo-4B-2C-4P (wt.%) amorphous/nanocrystalline multilayered coatings were synthesized using the atmospheric plasma spraying method with different power/heat input to vary the degree of melting. Microstructural and compositional characterization results showed that both amorphicity and porosity decreased with increasing plasma power. Higher hardness was observed at elevated power due to the presence of less porosity and more amount of hard intermetallic phases in the amorphous matrix. Wear behavior of the coatings was investigated under two different modes viz. reciprocating mode and unidirectional rotating mode to reflect the real-life service conditions. Results of dry sliding wear test revealed that improved wear resistance for coatings synthesized at higher plasma power input is attributed to the formation of well-adhered splats and presence of higher amount of intermetallic phases. Interestingly, the specific wear rate and coefficient of friction values obtained by performing the wear test in rotating mode were lower compared to that in reciprocating mode. Most importantly, a transition in wear mechanism was envisaged as mode of wear changes, i.e., fatigue dominated in case of the reciprocating mode to abrasion dominated in the rotating mode.

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Acknowledgments

The author, T. Laha thankfully acknowledges Science and Engineering Research Board, Department of Science and Technology, Govt. of India (CRG/2020/000738) and Defence Research and Development Organisation, Govt. of India (ERIP/ER/202101002/M/01/1783) for financial support.

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  1. Department of Metallurgical and Materials Engineering, Indian Institute of Technology Kharagpur, Kharagpur, West Bengal, 721302, India

    Md Akif Faridi, Sapan K. Nayak, D. K. V. D. Prasad, Amit Kumar & Tapas Laha

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This article is part of a special topical focus in the Journal of Thermal Spray Technology on New and Emerging Markets in Thermal Spray. The issue was organized by Dr. Andrew Vackel, Sandia National Laboratories; Dr. John Koppes, TST Engineered Coating Solutions; Prof. Bertrand Jodoin, University of Ottawa; Dr. Dheepa Srinivasan, Pratt and Whitney; and Prof. Shrikant Joshi, University West.

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Faridi, M.A., Nayak, S.K., Prasad, D.K.V.D. et al. Effect of Microstructure and Phase Evolution on the Wear Behavior of Fe-Based Amorphous/Nanocrystalline Composite Coatings Synthesized by Plasma Spraying. J Therm Spray Tech 32, 2054–2067 (2023). https://doi.org/10.1007/s11666-023-01631-0

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