Abstract
Abstract This paper presents the adhesive strength results of FeCr and FeCoCr deposits produced by electric arc thermal spray process on carbon steel plates. Five chemical compositions were tested to give a large panel of possibility. Coatings were characterized by several methods to result in a performance screening. The main assessment of microstructural morphology was made by scanning electron microscopy (SEM). The mechanical strength of coatings was evaluated by standard pull-off test. The corrosion resistance was analyzed in salt-spray test. The morphology of coatings exhibits characteristics of lamellar microstructures with incompletely melted particles together with a distribution of similarly oriented oxides. The adhesive strength of FeCoCr alloy coatings was higher amongst all studied conditions. All sealed conditions presented low corrosion in salt-spray exposure. Additionally, a new FeCoCr alloy was studied to reduce pores and microcracks that are frequently found in traditional FeCr and FeCrNi alloys. Based on the performed characterizations, the findings suggested that the FeCoCr deposition, with an epoxy sealing, is suitable to be used as an efficient coating of carbon steel in aggressive marine environments.
Highlights
Thermal spraying (TS) is a deposition technique where a spray of molten particles is directed to the substrate to form the coating
The morphology of coatings exhibit characteristics of lamellar microstructures with the long axis of impacted splats oriented along the substrate surface
The coatings were characterized by morphological aspects, corrosion and adhesion tests, and the most relevant conclusions are summarized as following:
Summary
Thermal spraying (TS) is a deposition technique where a spray of molten particles is directed to the substrate to form the coating. It is used for protection of parts against wear, corrosion and high temperatures. Thermal spraying processes are applied for repairing damaged and worn parts [1,2,3,4]. According to Fukanuma et al [4], the thermal spray consolidation of particulate materials is essentially a thermomechanical forming process, involving a combination of solid (unmelted or partially resolidified) and liquid phases. The thermal energy of the process heats the injected particles at temperature close to their melting points as well as the coating/substrate surface, during the deposition
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