Microstructure and Corrosion Behavior of Fe-Based Austenite-Containing Composite Coatings Using Supersonic Plasma Spraying

The Fe-based austenite-containing composite coatings with various contents (3 vol.%, 6 vol.%, 9 vol.%, 12 vol.%) of austenite powder additions were created by supersonic plasma spraying on 45 steel substrates. The microstructure, phase composition, microhardness, and porosity of the composite coatings were examed. Moreover, special attention was paid to the effect of austenite powder on the corrosion resistance of the austenite-containing composite coatings. The results found that the addition of austenite powders could significantly improve the corrosion resistance of Fe-based coatings, which is mainly due to three correlated phenomena caused by the austenite particles. First, austenite particles significantly reduce the porosity of the austenite-containing composite coatings and form a denser coating structure due to their low melting point and good chemical compatibility with the Fe-based alloy. Further, austenite particles help to refine the grains and increase the grain boundary density. Last but not least, austenite particles help to generate more diffusely distributed second phases in the coating, improving the chemical homogeneity and hardness of the coating.

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