Abstract
High-pressure gas atomization was employed to prepare the Fe-based Fe50Cr24Mo21Si2B3 alloy powder. The effect of flow rate of atomizing gas on the median powder diameter was studied. The results show that the powder size decreased with increasing the flow rate of atomizing gas. Fe-based alloy coatings with amorphous phase fraction was then prepared by high velocity oxygen fuel spraying (HVOF) of gas atomized Fe50Cr24Mo21Si2B3 powder. Microstructural studies show that the coatings present dense layered structure and low porosity of 0.17% in about 200 μm thickness. The Fe-based alloy coating exhibits an average hardness of about 1230 HV. Our results show that the HVOF process results in dense and well-bonded coatings, making it attractive for protective coatings applications.
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