Journal of Thermal Spray Technology

, Volume 28, Issue 1–2, pp 63–75 | Cite as

Influence of Powder Size on the Corrosion and Wear Behavior of HVAF-Sprayed Fe-Based Coatings

  • K. Bobzin
  • M. Öte
  • M. A. Knoch
  • J. SommerEmail author
Peer Reviewed


The goal of this study is to investigate the influence of the powder size on the coating properties and to gain insights into the underlying mechanisms. Therefore, FeCrB/WC-Co coatings were produced by HVAF spraying using different powder sizes. The used FeCrB/WC-Co feedstock materials exhibit an identical chemical composition with varying powder sizes of − 45 + 11 (Bobzin et al. (in Proceedings of ITSC—international thermal spray conference and exposition, Düsseldorf, pp. 339–345, 2017. ISBN: 978-3-96144-000-9), − 32 + 11 (Bobzin et al. in Proceedings of 20. WTK—Werkstofftechnisches Kolloquium, Chemnitz, 2018. ISBN: 978-3-00-058901-0) and − 20 + 3 µm. These coatings were subsequently analyzed with regard to their microstructure and phase composition, as well as their wear and corrosion behavior. All HVAF-sprayed FeCrB/WC-Co coatings exhibited a very dense microstructure. It was observed that coatings, which were produced with a finer powder size and identical chemical composition, showed reduced crack formation in the coating at high powder feed rates and lower current densities at high polarizations. Furthermore, the presented HVAF-sprayed FeCrB/WC-Co coatings exhibited an increased sliding wear and corrosion resistance compared to a sealed wire-arc-sprayed reference coating. The investigation also revealed that the powder size of the FeCrB/WC-Co feedstock material influences the microstructure and the phase composition of the resulting coating. It is assumed that the finer powder size of the HVAF-sprayed FeCrB/WC-Co coatings results in partly amorphous coatings, which might improve the corrosion resistance.


applications corrosion protection feedstock HVAF iron alloys paper industry processing wear-resistant coatings 



This work based on the DFG project BO 1979/45-1 “Resource efficient production of novel Fe-based coatings for large-area applications by AC-HVAF coating process.” The authors gratefully acknowledge the financial support of the German Research Foundation (DFG).


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Copyright information

© ASM International 2018

Authors and Affiliations

  1. 1.Surface Engineering InstituteRWTH Aachen UniversityAachenGermany

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