Abstract
Abstract Molds made of grey iron for casting iron are subjected to severe temperature fluctuations very similar to the die casting process except for the high pressure erosion that occurs due to molten metal. Therefore, the main life limiting damage for molds is the formation of surface cracks arising from thermal fatigue. Various flame and plasma sprayed coatings were investigated to extend the life of molds for casting iron. Coating materials studied include plasma sprayed ceramic coatings with bond coat (NiCrAl, NiCrAlY, and NiCrAlCoY) as well as powder flame sprayed oxidation resistant alloys (NiCr, NiAl, and NiCrAl). The results of simulated cyclic furnace tests from room temperature to 1100°C in air indicated that the failure occurred along the interface between the bond coat and the iron substrate due to iron oxidation rather than the interface between the ceramic coating and the bond coating for superalloy substrate. The results of field tests are also discussed.
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