Microstructure and wear resistance of Fe-based amorphous metallic coatings prepared by HVOF thermal spraying

Amorphous metallic coatings with a composition of Fe ₄₈Cr ₁₅Mo ₁₄C ₁₅B ₆Y ₂ were fabricated by means of high velocity oxygen fuel (HVOF) thermal spraying process. The microstructure and wear performance of the coatings were characterized simultaneously in this article. It is found that the coatings present a dense layered structure with the porosity below 1.5%. The coatings primarily consist of amorphous matrix and some precipitated nanocrystals, though a fraction of Fe-rich phases and oxide stringers also formed during deposited process. High thermal stability enables the amorphous coatings to work below 920 K temperature without crystallization. Depending on the structural advantage, the amorphous coatings exhibit high average microhardness of 997.3 HV _0.2, and excellent wear resistance during dry frictional wear process. The dominant wear mechanism of amorphous coating under this condition is fatigue wear, leading to partial or entire flaking off of the lamellae. In addition, the appearance of oxidative wear accelerates the failure of fatigue wear.