Effect of Nano-Y2O3 on Microstructure and Crack Formation in Laser Direct-Deposited In Situ Particle-Reinforced Fe-Based Coatings

Abstract

In situ hard-particle-reinforced Fe-based composite coatings were prepared on Q235 steel substrates by direct laser deposition using Fe-based alloy powders containing 2 wt.% B, 3 wt.% Si and 1-3 wt.% nano-Y2O3. The microstructures, phase compositions, hardnesses and wear resistances of the deposited coatings with different nano-Y2O3 contents were studied using metallographic microscopy, scanning electron microscopy, x-ray diffraction, transmission electron microscopy, microhardness tests and pin-on-disk abrasion tests (MMW-1A), respectively. The results showed that the appropriate addition of Y2O3 played a role in grain refinement and in decreasing the number of brittle phases and impurity elements in the grain boundaries. Consequently, the number of cracks in the laser-deposited coating also decreased. The Fe-based composite coatings were mainly composed of α-Fe, γ-Fe and in situ-produced reinforced particle phases, such as Cr23C6, Cr7C3, (Cr, Fe)7C3, Fe2B, and CrFeB. When the content of nano-Y2O3 was 2 wt.%, a Fe-based composite coating with a thickness of 4 mm that was free of cracks was obtained, and its surface hardness reached 650HV. Moreover, the wear resistance of the coating with 2 wt.% nano-Y2O3 was the best among the samples studied. The presence of nano-Y2O3 increased the solubility of Cr and Si in the solid solution, which eliminated the residual austenite region, and as a result, the phase transformation from γ-Fe to α-Fe was restrained and the transformation stress was also limited, thereby decreasing the probability of cracks in the coatings.