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| Abstract No.: |
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Scheduled at:
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Thursday, May 12, 2016, Room 3C + 3D 12:00 PM
Iron-based Coatings
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| Title: |
Highly economical Fe-based protective coating system by novel material design and full utilization of the atomized powder
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| Authors: |
Lidong Zhao* / RWTH Aachen University, Germany
Kirsten Bobzin / Surface Engineering Institute, RWTH Aachen University, Germany
Mehmet Öte/ Surface Engineering Institute, RWTH Aachen University, Germany
Thomas Frederik Linke/ Surface Engineering Institute, RWTH Aachen University, Germany
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| Abstract: |
Increasing prices of raw materials of Ni, Co and Mo have recently stimulated the interest in developing Fe-based protective coatings. In this study, a novel economical Ni- and Mo-free wear and corrosion resistant FeCrMn alloy was designed. Spray powders of this alloy were produced through gas atomization. The total atomized powder was fractioned to -90 +45 µm, -45 +25 µm, -25 +10 µm and -10 µm. These powders were characterized in terms of their size distributions and morphologies. Subsequently, they were sprayed by a three-cathode plasma generator TriplexPro-210. Spray parameters were developed to produce a dense and low oxide microstructure. Parameter variation included plasma current, plasma gas and spray nozzle. It was found that fine powders with fractions of -25 +10 µm and -10 µm show a significantly higher affinity to oxidation than coarser ones. Nevertheless, a dense microstructure in low oxide content could be realized using suitable parameters even with the finest powder. The results show that a full utilization of the atomized powder can be realized by three-cathode plasma spraying due to its wide parameter window. The deposition efficiencies of the powders were determined. The average deposition efficiency is more than 70 %. In this way, the atomized powder can be used very efficiently. This contributes additionally to the high economical potential of this coating system which exhibits a hardness of up to 600 0,1 HV and significantly higher corrosion resistance compared to carbon steels as well as cast irons.
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