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<p>The objective of this study is to develop iron aluminide (Fe<sub>3</sub>Al) coating of thickness ≈150&#xa0;µm on mild steel (MS) using synthesized iron aluminide powder. The coatings have been developed using various forms of high velocity oxy fuel (HVOF) process such as conventional designated as normal, substrate cooled and hybrid-HVOF processes. The x-ray diffraction results showed that the Fe<sub>3</sub>Al powder exhibits a disordered A2 phase while the HVOF-sprayed coatings display an ordered DO<sub>3</sub> phase. An improved microhardness has been achieved with the hybrid process (833 ± 38 HV) compared to substrate cooled (653 ± 35 HV) and normal HVOF (693 ± 35HV) processes. The Fe<sub>3</sub>Al-coated specimens were evaluated for their high-temperature isothermal oxidation behavior by subjecting them to 200, 400, 600 and 800&#xa0;°C temperatures under atmospheric conditions. It is observed that at temperature of 600&#xa0;°C and beyond there is a formation of needle-like structure irrespective of the variant of the process used. The energy-dispersive x-ray analysis revealed these to be rich in Fe and O, indicating the formation of iron oxide. The coatings were also evaluated for their high-temperature erosion resistance and the erosion studies performed at elevated temperatures of 800&#xa0;°C revealed no delamination of the coating, thereby indicating their suitability for high-temperature applications.</p>

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Microstructural and High-Temperature Oxidation Behavior of Iron Aluminide Coatings Developed by Hybrid and Conventional HVOF Processes

  • 期刊论文

  • 发表日期：

    2025年11月3日

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  • Meenu Srivastava,
  • Nikhil Pandita,
  • R. P. Sreekanth Chakradhar,
  • Chetan,
  • Siju John,
  • V. Praveen Kumar,
  • Harish C. Barshilia

摘要

The objective of this study is to develop iron aluminide (Fe3Al) coating of thickness ≈150 µm on mild steel (MS) using synthesized iron aluminide powder. The coatings have been developed using various forms of high velocity oxy fuel (HVOF) process such as conventional designated as normal, substrate cooled and hybrid-HVOF processes. The x-ray diffraction results showed that the Fe3Al powder exhibits a disordered A2 phase while the HVOF-sprayed coatings display an ordered DO3 phase. An improved microhardness has been achieved with the hybrid process (833 ± 38 HV) compared to substrate cooled (653 ± 35 HV) and normal HVOF (693 ± 35HV) processes. The Fe3Al-coated specimens were evaluated for their high-temperature isothermal oxidation behavior by subjecting them to 200, 400, 600 and 800 °C temperatures under atmospheric conditions. It is observed that at temperature of 600 °C and beyond there is a formation of needle-like structure irrespective of the variant of the process used. The energy-dispersive x-ray analysis revealed these to be rich in Fe and O, indicating the formation of iron oxide. The coatings were also evaluated for their high-temperature erosion resistance and the erosion studies performed at elevated temperatures of 800 °C revealed no delamination of the coating, thereby indicating their suitability for high-temperature applications.