Abstract
In this study, using mixtures of pure Al, Si, Mn, and Fe powders, the α-Al9FeMnSi intermetallic compound was formed onto AISI 304L stainless steel samples by reactive sintering. The processing parameters were temperature (800, 850, and 900 °C) and applied pressure (15 and 20 MPa), using a constant holding time of 7200 s. In this paper, the influence of pressure and temperature on the microstructure, microhardness, and wear resistance of the formed layers was studied. Using X-ray diffraction (XRD), scanning electron microscopy (SEM), microhardness testing, and wearing measurements (pin on disc tests), the cross-section and top side of the coatings were observed and analyzed. We were able to determine the phase composition of cladded layers and interfaces as well as their morphology. The results indicated that several layers were formed during reactive sintering, i.e., an Al-diffusion layer on the top of the substrate, an interface, and the α-Al9FeMnSi coating itself. The microhardness values of the different layers formed were determined, ranging from 400 to 500 HV for the intermetallic coating, to 120 HV for the substrate. In this way, it was found that the formed intermetallic coating is suitable to increase the corrosion resistance of stainless steel. Additionally, all the coating showed high adherence to the substrate, exhibiting high microhardness and wear resistance. Pin on disc wearing tests showed the wearing mechanisms are predominantly delamination and ablation of the cladded layers and substrate.
Highlights
In terms of alloy usage and type, austenitic stainless steels represent the largest stainless steel family [1,2]
The material utilized as substrate in this paper was the AISI 304L stainless steel (10 mm disks of diameter and 5 mm of thickness)
The stoichiometric powder mixture ratio paired that of the α-Al9 FeMnSi intermetallic phase
Summary
In terms of alloy usage and type, austenitic stainless steels represent the largest stainless steel family [1,2]. The use of stainless steel materials has continually increased thanks to their excellent corrosion resistance in various environments [3] and numerous industrial applications [4,5]. There is still a lack of performance at high wearing conditions, which may restrict its longevity and use. Aluminum intermetallic type coatings could be an acceptable substitute for enhancing the wearing tension of stainless steel components [6,7]. The high thermal stability of these components can be enhanced. The idea of directly synthesizing AlSiFeMn-type intermetallic compounds using pure elements onto stainless steel substrates for coating reasons arose
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