Abstract
Plasma spraying was employed to form coating with the characteristics of liquid-quenched alloys. To achieve ultrarapid quenching (i.e. splat cooling) of the type 431 stainless steel alloys, melt-atomized powder was plasma sprayed onto copper substrates cooled with liquid nitrogen (LN). Three different quenching conditions were employed, including continous coverage of the substrate with a flowing film of LN, and quenching into LN intermittently during the actual spray coating process. Transmission electron microscopy was employed to analyze the sprayed coatings, and their adhesion and microhardness were determined. It was found that increased quench rates give rise to finer grain and second-phase distributions as well as a tendency toward cubic and austenite phases. Increased quench rates resulted in both enhanced microhardness and tensile adhesion strength. The underlying reasons for these effects will be discussed.
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