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<p>Key components of marine equipment are subjected to harsh working environments involving abrasion and corrosion for extended periods, significantly accelerating surface failure. Applying a thermal spray coating on its surface is an effective strategy to address this issue. In this work, Fe-based coatings are successfully fabricated via plasma-enhanced high-speed arc spraying (PE-HAS), with a focus on investigating the coating formation process, microstructure, mechanical properties, wear resistance, and corrosion resistance. The results show that the solid wires serve as melting electrodes through preheating, heat transfer, heat, and tip tear melting processes in the PE-HAS process. The tip of the solid wire is delivered into the high-temperature region and then blown into droplets of varying shapes by the plasma jet. The flight debris exhibits small particle size and high flight velocity, and the formed layer pieces have a similar degree of lap matching to form a low-porosity dense structure. Consequently, the solid wire coating demonstrates high bond strength value (46.04&#xa0;MPa) and corrosion resistance (corrosion potential: -0.357&#xa0;V, corrosion current density of 1.17 × 10<sup>− 4</sup> A/cm<sup>2</sup>). For cored wires, the metallic sheath melts first, and the exposed core powder is subsequently continuously melted by the plasma jet. However, the flattening ratio of the droplets in the cored wire coating is relatively low, and the overlapping of splats leads to a higher porosity. Nevertheless, this coating still features fine grain size, small droplet size, high flight velocity, similar splat sizes, and high splat matching/overlap, forming a low-porosity dense structure. Under the combined strengthening mechanisms of solid solution strengthening and grain refinement strengthening, the cored wire coating exhibits fine grains and dispersed unmelted particles, endowing it with high hardness (555.4 HV<sub>0.1</sub>) and excellent wear resistance (friction coefficient of 0.39). This research provides new insights for designing high-strength metal-based coatings for various applications.</p> Graphical Abstract <p></p>

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Plasma-Enhanced High-Speed Arc Spraying of an Fe-Based Coating: Molding Mechanism and Performance Research

  • 期刊论文

  • 发表日期：

    2025年10月17日

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  • Rui Gao,
  • Tianhao Li,
  • Ming Liu,
  • Qiqing Peng,
  • Jie Zhang,
  • Yanfei Huang,
  • Kaiwen Bai,
  • Yujie Zhou,
  • Tengda Pan,
  • Guo Jin,
  • Haidou Wang

摘要

Key components of marine equipment are subjected to harsh working environments involving abrasion and corrosion for extended periods, significantly accelerating surface failure. Applying a thermal spray coating on its surface is an effective strategy to address this issue. In this work, Fe-based coatings are successfully fabricated via plasma-enhanced high-speed arc spraying (PE-HAS), with a focus on investigating the coating formation process, microstructure, mechanical properties, wear resistance, and corrosion resistance. The results show that the solid wires serve as melting electrodes through preheating, heat transfer, heat, and tip tear melting processes in the PE-HAS process. The tip of the solid wire is delivered into the high-temperature region and then blown into droplets of varying shapes by the plasma jet. The flight debris exhibits small particle size and high flight velocity, and the formed layer pieces have a similar degree of lap matching to form a low-porosity dense structure. Consequently, the solid wire coating demonstrates high bond strength value (46.04 MPa) and corrosion resistance (corrosion potential: -0.357 V, corrosion current density of 1.17 × 10− 4 A/cm2). For cored wires, the metallic sheath melts first, and the exposed core powder is subsequently continuously melted by the plasma jet. However, the flattening ratio of the droplets in the cored wire coating is relatively low, and the overlapping of splats leads to a higher porosity. Nevertheless, this coating still features fine grain size, small droplet size, high flight velocity, similar splat sizes, and high splat matching/overlap, forming a low-porosity dense structure. Under the combined strengthening mechanisms of solid solution strengthening and grain refinement strengthening, the cored wire coating exhibits fine grains and dispersed unmelted particles, endowing it with high hardness (555.4 HV0.1) and excellent wear resistance (friction coefficient of 0.39). This research provides new insights for designing high-strength metal-based coatings for various applications.

Graphical Abstract