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Structural characteristics and tribological properties of an ultrafine-grained Al–40Si–5Fe coating prepared by supersonic plasma spraying

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High silicon aluminum alloy coatings (HSAACs) are characterized by high surface hardness and excellent wear resistance, and the fineness has a significant impact on their properties. In this study, Al–40Si–5Fe coating was prepared by supersonic plasma spraying using Al–35Si–4Fe powder as raw material. The coating contains a variety of strengthening structures such as amorphous, nanocrystalline and supersaturated solid solution. The average hardness of the coating reached up to 465.3 ± 24.4HV0.2, which was much higher than that of the Al–Si alloys/coatings prepared by various processes. Under the test conditions, the wear mechanism of the coating was dominated by fatigue wear with slight abrasive wear, and the wear rate was 1.88 × 10–4 mm3/N. A large amount of refined Si phase in the oxide film on the worn surface effectively prevented the cracking and spalling of the oxide film.

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Funding

This study was supported by the National Natural Science Foundation of China (52075543, 52130509 and 52122508).

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Authors and Affiliations

  1. School of Materials Science and Engineering, Hebei University of Technology, Tianjin, 300130, China

    Hao-bo Xu & Guo-lu Li

  2. National Key Laboratory for Remanufacturing, Army Academy of Armored Forces, Beijing, 100072, China

    Hao-bo Xu, Guo-zheng Ma, Yang Song, Xian-yong Zhu, Ming Liu & Hai-dou Wang

  3. National Engineering Research Center for Remanufacturing, Army Academy of Armored Forces, Beijing, 100072, China

    Hai-chao Zhao & Hai-dou Wang

  4. Defense Innovation Institute, Academy of Military Science, Beijing, 100071, China

    Peng-fei He

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  1. Hao-bo Xu
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Contributions

HX: Writing—original draft data curation formal analysis. GM: Writing—review and editing funding acquisition. PH: Writing—review and editing conceptualization. GL: Writing—review and editing. YS: Writing—review and editing. XZ: Writing—review and editing. ML: Writing—review and editing. HZ: Writing—review and editing. HW: Writing—review and editing.

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Correspondence to Guo-zheng Ma or Guo-lu Li.

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Xu, Hb., Ma, Gz., He, Pf. et al. Structural characteristics and tribological properties of an ultrafine-grained Al–40Si–5Fe coating prepared by supersonic plasma spraying. Journal of Materials Research 39, 220–230 (2024). https://doi.org/10.1557/s43578-023-01213-4

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