Abstract
Abstract : Spray metal forming has been used to produce deposits of iron-based alloys DAR1A, DAR27, DAR35, and BMA1. The deposits were made on tubular and flat plate substrates and were up to 1.25 inches in thickness. Most of the deposits were found to be partially amorphous in the as-sprayed condition. Measurements were made of microhardness and porosity, and corrosion and wear tests were conducted. Severe cracking occurred in the thick section spray formed deposits, most likely arising from thermal stresses. The use of a pre-heated substrate is being investigated to minimize or eliminate this cracking. The spray formed deposits had high hardness (900 to 1200 HV), low porosity, (0.5 to 3%), and better wear resistance than a conventional hull steel and a tool steel. In a standardized salt fog chamber test, the spray-formed alloys were found to corrode like a conventional hull steel. This is probably a result of the partially devitrified nature of the spray-formed material.
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