Mechanical properties of thermally sprayed Fe based coatings

An additional coating against wear or corrosion on component parts is required for many applications. These coatings protect the substrate material against external influences, thus increasing the economic lifetime of the component. Coating processes such as build-up welding and thermal spraying are well established and commonly used. The thermal spray process, in particular, permits deposition of metals, ceramics, or cermets materials to produce near net shape coatings on complex surface geometries. However, commonly used coating materials suffer from high raw material costs, thus decreasing the cost effectiveness of the coating process. Fe based materials are low priced and possess noteworthy mechanical properties; they thus provide the possibility of substituting the expensive Ni and Co based materials commonly used for thermal spray processes. In this work, 2 mm thick high velocity oxyfuel sprayed Fe based coatings in the as sprayed and thermally sprayed and hot isostatic pressed condition were investigated with respect to their mechanical and wear properties. Additionally, the fracture surface was investigated by scanning electron microscopy to characterise the fracture behaviour. It could be demonstrated that the substrate and the heat treatment have the greatest impact on the shear strength of thermally sprayed cold work tool steel. It is shown that the substrate materials as well as the heat treatment are promoting diffusion processes across the interface between the coating and the substrate. Hence, a material integrated bond is formed. The microstructures of the thermally sprayed coatings become more important regarding the mechanisms of failure of the four point bending tests. The material strength is influenced by quenching and tempering and the specimen deflection is influenced by diffusion reactions induced by hot isostatic pressing treatment. The thermally sprayed coatings in the as sprayed condition feature the highest wear resistance due to their hardness.