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An Overview of Thermally Sprayed Fe-Cr-Nb-B Metallic Glass Coatings: From the Alloy Development to the Coating’s Performance Against Corrosion and Wear

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Abstract

Fe-based bulk metallic glass (BMG) presents unique tribological and electrochemical properties. Given the inherent brittle nature and dimensional limitations of Fe-based BMGs, technological and scientific efforts are focused on their use for surface engineering solutions. Fe-based BMG coatings are promising to protect steel components operating in a wide array of hostile environments, with encouraging resistance against corrosion and wear. This article summarizes the progress of Fe-Cr-Nb-B glassy coatings in terms of alloy design, glass-forming ability, crystallization, powder production, thermally-sprayed coatings, and how the microstructural features dictate the basket of properties. The strategy for selecting the alloy composition with high glass-forming ability is discussed based on thermodynamic calculations. Two main methods are presented for feedstock powder production: gas-atomization and high-energy ball milling. Different processing routes to produce Fe-Cr-Nb-B coatings and deposits are summarized: detonation spraying, high-velocity oxygen fuel, flame spraying, non-vacuum electron beam cladding, and spray forming. The resulting phases (glassy and crystalline), microstructures, porosity levels, and hardness values are comparatively discussed and related to the corrosion and wear resistances. The final part of the work is dedicated to a new generation of Fe-based BMGs that emerged as contender to further enhance the corrosion and wear resistances.

Graphical Abstract

Illustration of the processes used to produce Fe-Cr-Nb-B alloys covered in this review. The thermal spraying routes considered are flame spraying (FS), high-velocity oxygen fuel (HVOF), and detonation spraying. Spray forming (SF) and non-vacuum electron beam cladding were also evaluated. (a) Secondary electron (SE) scanning electron (SEM) micrographs of gas-atomized, GA, and milled, M, feedstock powders. Cross-sectional backscattered electron (BSE) SEM imaging of coatings: (b) ~220-μm-thick from detonation spraying from gas-atomized feedstock, (c) ~280-μm-thick HVOF from gas-atomized feedstock, (d) ~200-μm-thick HVOF from milled feedstock, (e) ~200-μm flame spraying from gas-atomized feedstock, (f) ~220-μm flame spraying from milled feedstock, (g) ~1300-μm non-vacuum electron beam cladding from gas-atomized feedstock, and (h) spray formed ~5000-μm-thick deposit formed from the liquid. All images for the Fe60Cr8Nb8B24 alloy, except (b) Fe66Cr10Nb5B19 alloy and (g) Fe62Cr10Nb12B16 alloy. Bright phases identified as (Fe,Cr)NbB. [This figure is related to the manuscript "An overview of thermally sprayed Fe-Cr- Nb-B metallic glass coatings – From the alloy development to the coating’s performance against corrosion and wear"].

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Acknowledgments

Guilherme Yuuki Koga gratefully acknowledges the financial support of FAPESP (Post-Doctorate Grant No. 17/09237-4 and Scientific Initiation Grant No. 12/10631-5), CNPq (Master Grant No. 153269/2013-8 and Universal Grant No. 407651/2021-7), and CAPES-BRAFITEC (Exchange Grant No. 2778/11-4). All authors are grateful for the financial support granted by FAPESP (Thematic Project Grant Nos. 13/05987-8 and 05/59594-0). The authors also thank the Laboratory of Structural Characterization (LCE) and the Center for Characterization and Development of Materials (CCDM) of the Federal University of São Carlos for the characterization facilities access. The Hydro-Quebec (HVOF and Wear facilities, Canada), Lavrentyev Institute of Hydrodynamics SB RAS (Detonation Spraying facility, Russia), Novosibirsk State Technical University (Electron Beam Cladding facility, Russia), Université Grenoble Alpes (Corrosion-LEPMI and Processing-SIMaP facilities, France), Petrobras SA (funding, Brazil), and Villares Metals SA (supply of stainless steels, Brazil) are acknowledged. This work results from the collaboration of our group with different researchers over the past decade, whose publications were used as the cornerstone of this review. We are thus thankful for the fruitful discussion and exchange consolidated with Dr. Robert Schulz (Hydro-Quebec), Prof. Ricardo Pereira Nogueira and Prof. Virginie Roche (LEPMI), Prof. Dina Dudina (Lavrentyev Institute of Hydrodynamics), Prof. Ivan Bataev (Novosibirsk State Technical University), Prof. Juno Gallego (UNESP), Prof. Akihisa Inoue (Tianjin University/King Abdulaziz University) and Dr. Alain Reza Yavari (SIMaP). We also thank the valuable effort and contribution of previous students that have worked on Fe-Cr-Nb-B alloys in our group: M.Sc. Ana Karla Melle, Dr. Alexandre Nascimento, M.Sc. Diego Santana, Dr. Tales Ferreira, M.Sc. Diego Coimbrão, and Dr. Yaofeng Guo; we also thank Ms. Ivanna Kuchumova, who conducted her Ph.D. on Fe-Cr-Nb-B coatings in the Lavrentyev Institute of Hydrodynamics SB RAS.

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  1. Department of Materials Science and Engineering, Federal University of São Carlos, Rod. Washington Luis, km 235, São Carlos, SP, CEP 13565-905, Brazil

    Guilherme Yuuki Koga, Claudemiro Bolfarini, Claudio Shyinti Kiminami, Alberto Moreira Jorge Jr. & Walter José Botta

  2. Federal University of São Carlos, Center for Characterization and Development of Materials (CCDM), Rod. Washington Luis, São Carlos, SP, CEP 13565-905, Brazil

    Guilherme Yuuki Koga

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  1. Guilherme Yuuki Koga
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This article is part of a special topical focus in the Journal of Thermal Spray Technology on High Entropy Alloy and Bulk Metallic Glass Coatings. The issue was organized by Dr. Andrew S.M. Ang, Swinburne University of Technology; Prof. B.S. Murty, Indian Institute of Technology Hyderabad; Distinguished Prof. Jien-Wei Yeh, National Tsing Hua University; Prof. Paul Munroe, University of New South Wales; Distinguished Prof. Christopher C. Berndt, Swinburne University of Technology. The issue organizers were mentored by Emeritus Prof. S. Ranganathan, Indian Institute of Sciences.

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Koga, G.Y., Bolfarini, C., Kiminami, C.S. et al. An Overview of Thermally Sprayed Fe-Cr-Nb-B Metallic Glass Coatings: From the Alloy Development to the Coating’s Performance Against Corrosion and Wear. J Therm Spray Tech 31, 923–955 (2022). https://doi.org/10.1007/s11666-022-01371-7

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