Abstract
This study describes the development of cost-effective FeCrB-coatings and the evaluation of these novel coatings against impact loads. The cost reduction is achieved by using a new and economical iron-based feedstock material with a small particel size distribution, which can be processed at high feeding rates with the HVAF process. The reduced particle size distribution enhances the application of near-net-shape coatings, minimizing the need for expensive, time-consuming grinding postprocesses. Thicker coatings usually result in higher thermal insulation, whereas thin near-net-shape coatings can reduce the thermal insulation. Dense FeCrB and FeCrB/WC-Co coatings were applied by HVAF with feeding rates of ṁ = 200 g/min and a particle size distribution of -20 + 3 μm. Through curvature measurements during the application it is shown that by integrating WC-Co into FeCrB the tensile residual stress state of the coating was minimized, which in turn increased the fracture toughness of the coating. The evaluation of the impact resistance was investigated by an impact test. The results show that the crater volume was halved by adding WC-Co in the FeCrB-coating. However, it is shown that the plastic deformability of the coating is minimized and a stronger cracking behavior can be observed.
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