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<p>Although iron-based composite coatings are widely used to improve the surface performance of structural steels, simultaneously achieving high hardness, wear resistance, and impact toughness remains a considerable challenge due to inherent strength-toughness trade-offs. In this work, a Fe-Mo-V-B-C alloy powder was designed and synthesized by gas atomization, and subsequently deposited on Q235 steel substrates via plasma spraying to fabricate iron-based composite coatings. Microstructural characterization indicates that the coating is composed of a martensitic matrix reinforced by petal-like VC and blocky to skeleton Mo<sub>2</sub>B eutectic phases, with volume fractions of 16.5 and 41.6%, respectively, uniformly distributed throughout the coating. The synergistic reinforcement of these hard phases results in a Vickers hardness of 991HV<sub>0.5</sub>, a low friction coefficient of 0.409, and a reduced wear loss of 4.5&#xa0;mg. Wear is dominated by subsurface-crack-induced spalling, combining abrasive and adhesive mechanisms. Importantly, the coating exhibits excellent fracture toughness (50.4&#xa0;MPa·m<sup>1/2</sup>) and impact toughness (111.63&#xa0;J/cm<sup>2</sup>). Fractographic analysis reveals shallow dimples and tearing ridges, characteristic of ductile fracture, where the skeleton Mo<sub>2</sub>B eutectic structure enhances toughness by deflecting cracks and prolonging their propagation paths. This work provides a feasible materials design strategy for iron-based coatings that reconcile hardness, wear resistance, and impact toughness, offering theoretical guidance for engineering applications requiring severe wear and impact conditions.</p>

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Microstructure and Synergistic Enhancement of Hardness, Wear Resistance, and Toughness in Plasma Sprayed Iron-Based Composite Coatings

  • 期刊论文

  • 发表日期：

    2026年7月29日

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  • Xiang Gao,
  • Jian Zhang,
  • Hongxuan Chen,
  • Yun Chen,
  • Xiaotong Pang

摘要

Although iron-based composite coatings are widely used to improve the surface performance of structural steels, simultaneously achieving high hardness, wear resistance, and impact toughness remains a considerable challenge due to inherent strength-toughness trade-offs. In this work, a Fe-Mo-V-B-C alloy powder was designed and synthesized by gas atomization, and subsequently deposited on Q235 steel substrates via plasma spraying to fabricate iron-based composite coatings. Microstructural characterization indicates that the coating is composed of a martensitic matrix reinforced by petal-like VC and blocky to skeleton Mo2B eutectic phases, with volume fractions of 16.5 and 41.6%, respectively, uniformly distributed throughout the coating. The synergistic reinforcement of these hard phases results in a Vickers hardness of 991HV0.5, a low friction coefficient of 0.409, and a reduced wear loss of 4.5 mg. Wear is dominated by subsurface-crack-induced spalling, combining abrasive and adhesive mechanisms. Importantly, the coating exhibits excellent fracture toughness (50.4 MPa·m1/2) and impact toughness (111.63 J/cm2). Fractographic analysis reveals shallow dimples and tearing ridges, characteristic of ductile fracture, where the skeleton Mo2B eutectic structure enhances toughness by deflecting cracks and prolonging their propagation paths. This work provides a feasible materials design strategy for iron-based coatings that reconcile hardness, wear resistance, and impact toughness, offering theoretical guidance for engineering applications requiring severe wear and impact conditions.