Structural characteristics and tribological properties of an ultrafine-grained Al–40Si–5Fe coating prepared by supersonic plasma spraying

High silicon aluminum alloy coatings (HSAACs) are characterized by high surface hardness and excellent wear resistance, and the fineness has a significant impact on their properties. In this study, Al–40Si–5Fe coating was prepared by supersonic plasma spraying using Al–35Si–4Fe powder as raw materia...

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Bibliographic Details
Published inJournal of materials research Vol. 39; no. 2; pp. 220 - 230
Main Authors Xu, Hao-bo, Ma, Guo-zheng, He, Peng-fei, Li, Guo-lu, Song, Yang, Zhu, Xian-yong, Liu, Ming, Zhao, Hai-chao, Wang, Hai-dou
Format Journal Article
LanguageEnglish
Published Cham Springer International Publishing 28.01.2024
Springer Nature B.V
Subjects
Abrasive wear
Aluminum base alloys
Amorphous materials
Applied and Technical Physics
Biomaterials
Chemistry and Materials Science
Fatigue tests
Fatigue wear
Fineness
Fracture mechanics
Inorganic Chemistry
Materials Engineering
Materials research
Materials Science
Mechanical properties
Nanotechnology
Oxide coatings
Plasma spraying
Raw materials
Silicon
Solid solutions
Spalling
Surface hardness
Tribology
Ultrafines
Wear mechanisms
Wear rate
Wear resistance
Supersonic plasma spraying
High silicon aluminum alloy coating
Ultrafine-grain structure
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Summary:High silicon aluminum alloy coatings (HSAACs) are characterized by high surface hardness and excellent wear resistance, and the fineness has a significant impact on their properties. In this study, Al–40Si–5Fe coating was prepared by supersonic plasma spraying using Al–35Si–4Fe powder as raw material. The coating contains a variety of strengthening structures such as amorphous, nanocrystalline and supersaturated solid solution. The average hardness of the coating reached up to 465.3 ± 24.4HV 0.2 , which was much higher than that of the Al–Si alloys/coatings prepared by various processes. Under the test conditions, the wear mechanism of the coating was dominated by fatigue wear with slight abrasive wear, and the wear rate was 1.88 × 10 –4 mm 3 /N. A large amount of refined Si phase in the oxide film on the worn surface effectively prevented the cracking and spalling of the oxide film. Graphical abstract
ISSN:0884-2914
2044-5326
DOI:10.1557/s43578-023-01213-4