Microstructure and Sliding Wear Behavior of Fe-Based Coatings Manufactured with HVOF and HVAF Thermal Spray Processes

A. Milanti, V. Matikainen, G. Bolelli, H. Koivuluoto, L. Lusvarghi, P. Vuoristo

    Research output: Contribution to journalArticleScientificpeer-review

    22 Citations (Scopus)


    The microstructure and micromechanical behavior of thermally sprayed Fe-based coatings manufactured with high-velocity oxygen fuel (HVOF) and high-velocity air fuel (HVAF) processes were investigated. Fe-Cr-Ni-Si-B-C and Fe-Cr-Ni-Mo-Si-B-C powders were used as the feedstock materials. The coatings showed a highly dense microstructure with near-zero oxidation. The microstructure of the feedstock powders was better retained when sprayed with HVAF process. Differential scanning calorimetry revealed two small exothermic peaks at about 600 °C for the HVOF-sprayed coatings, without any increase in weight in thermogravimetric analysis. It suggested the re-precipitation of carbides that were dissolved during spraying due to the higher particle temperature reported by spray diagnostics system during the HVOF process (≈1800 °C) compared to the HVAF one (≈1400 °C). Micro- and nano-indentations helped to show the difference in inter-lamellar cohesive strength and, in turn, in the particle deposition mechanism. Coatings sprayed with Fe-Cr-Ni-Mo-Si-B-C composition possessed higher sliding wear resistance than that of Fe-Cr-Ni-Si-B-C due to higher nano-hardness. More specifically, HVOF-sprayed Fe-Cr-Ni-Mo-Si-B-C coating showed the largest intra-lamellar hardness, the largest elasticity, and high quality of particle interfaces which resulted in lower sliding wear rate.

    Original languageEnglish
    Pages (from-to)1040–1055
    Number of pages16
    JournalJournal of Thermal Spray Technology
    Issue number5
    Early online date27 Apr 2016
    Publication statusPublished - Jun 2016
    Publication typeA1 Journal article-refereed


    • iron alloys
    • protective coatings
    • wear resistant coatings

    Publication forum classification

    • Publication forum level 1

    ASJC Scopus subject areas

    • Condensed Matter Physics
    • Materials Chemistry
    • Surfaces, Coatings and Films


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