Abstract
A billet of hypoeutectic high-chromium white iron (2.5% C, 19% Cr) was spray formed using gas-to- metal ratios of *0.9, *1.0, and *1.1. The as-sprayed material was close to full density and contained fine (Fe,Cr)7C3 carbides (27-30 vol%) uniformly distributed in a matrix consisting of pearlite and ferrite. Length of the carbides rarely exceeded 30 lm. This was in stark contrast to a conventionally cast starting material, which contained coarse (Fe,Cr)7C3 carbides (*22 vol%) non-uniformly distributed in a matrix consisting of austenite and marten- site. Length of the carbides in the cast material occasion- ally exceeded 100 lm. Varying gas-to-metal ratio between 0.9 and 1.1 did not result in any significant changes in carbide morphology, although slightly coarser carbide morphology was produced with the gas-to-metal ratio of 0.9. Regardless of the gas-to-metal ratio, the finest carbide morphology was found in the surface region of the spray- formed billet.
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