Abstract
In this study, a novel alloy FeCrMnBC was designed to protect machine parts of cast irons and carbon steels against wear and corrosion. Coatings of this alloy were deposited on cast iron substrates of EN-GJL-250 with a fine powder (−25+10μm) by a three-cathode plasma generator TriplexPro™-210. Particle in-flight velocities were determined using particle diagnostics. The coatings were characterized with regard to their microstructure, microhardness, wear resistance and corrosion behavior. The results have shown that very high particle velocities of more than 650m/s can be realized by means of three-cathode plasma spraying. The coatings exhibit dense microstructures with a porosity of less than2.5% and high microhardnesses up to 660HV0.1. The coating's microstructure and the oxidation of feedstock material during spraying depend strongly on spray parameters. The coatings show significantly higher scratch and wear resistance than classic stainless steel coating and cast iron substrate. A comparable corrosion resistance in a 5wt.% NaCl aqueous solution to that of 316L stainless steel coating was confirmed. This novel coating system presents great potential as highly economic coating solution for machine parts made of cast irons and carbon steels.
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