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2020 №07 (03) DOI of Article
2020 №07 (05)

Automatic Welding 2020 #07
Avtomaticheskaya Svarka (Automatic Welding), #7, 2020, pp. 32-40

Coatings based on Fe–Al intermetallics produced by the methods of plasma and supersonic air-gas plasma spraying

Yu.S. Borisov, A.L. Borisova, N.V. Vigilianska, О.P. Grіshchenko, M.V. Kolomytsev
E.O. Paton Electric Welding Institute of the NAS of Ukraine, 11, Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: office@paton.kiev.ua

The results of investigations of the structure and phase composition of gas-thermal coatings based on Fe–Al intermetallics are presented. Fe-Al intermetallics were chosen as a material of protective coatings due to their high heat and corrosion resistance and cost effectiveness as compared to many modern heat resistant materials. As spraying materials, powders of mechanical mixtures of Fe and Al as well as powders produced by mechanochemical synthesis of Fe–Al intermetallics by the treatment of mixtures of powders Fe and Al in a high-energy ball mill were used. The content of powder components corresponds to the intermetallics Fe3Al, FeAl and Fe2Al5. For spraying, the alloyed powders were used having the composition corresponding to the intermetallic Fe3Al. To increase the mechanical and physicochemical properties of the intermetallic, as alloying elements Ti, Mg, Cr, Zr, and La were used. The coating was produced by plasma and supersonic air-gas plasma spraying. It was found that in plasma coatings with FeAl powders, in addition to the initial phase (Fe3Al, FeAl and Fe2Al5), Fe and Al oxides are also present, due to which the microhardness of the coatings increases by about 1300 MPa relative to the initial powders. The microhardness of the plasma coating of the alloying powder Fe–TiAl 2 times increases relative to the initial powder due to the formation of the intermetallic phase FeTi in the coating. During spraying of mechanical mixtures, due to a low probability of contact interaction of Fe and Al particles during flight and rapid cooling of melts particles on the surface of the base, the synthesis of intermetallics does not have a time to develop and in the coatings no intermetallic phases are revealed. In the coatings produced by supersonic air-gas plasma spraying, the main phase is α-Fe(Al)-solid solution, which is the result of a high rate of melt hardening. 14 Ref., 4 Tabl., 8 Fig.
Keywords: FeAl intermetallic, powders, mechanochemical synthesis, mechanical mixture, plasma spraying, supersonic air-gas plasma spraying, coating, structure, microhardness

Received: 30.06.2020


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