Abstract
A Fe-Co-Mo alloy coating was successfully fabricated on 40Cr steels by plasma cladding with water-atomized powders. The coating exhibited a good metallurgical bonding with substrate and possessed no cracks or apparent pores, being particularly suited for plasma cladding. The microstructure of the as-cladded coating contained α-Fe matrix and netlike micrometer-sized strengthening phases comprising μ-intermetallic phases and a few η-carbide phases caused by substrate dilution and introduction of carbon element. Besides, Fe-Co-Mo coating could be hardened to the remarkable microhardness (849 HV0.2, 3.5 times as much as the substrate) after aging at 600 °C (the peak-aging temperature) by the precipitation of nanometer-sized μ phases. Meanwhile, the superior aggregation resistance and size stability of strengthening intermetallics at elevated temperatures could impede dislocation motion, postpone matrix softening and endow the coating with outstanding temper resistance. The high temper resistance could delay the change from slight wear to severe wear during high-temperature wear, making the wear mechanism mainly mild abrasive and oxidative wear. Therefore, the coating showed outstanding wear resistance and its superiorities became more pronounced as the temperature rises, with a wear rate of only 17 % of widely-used AISI H13 hot-working steels at 800 °C.
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