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<p>Powder plasma arc directed energy deposited (PPA-DED) has emerged as a promising technique for the fabrication of multi-component alloy coatings. However, the thermal cycling characteristics inherent to the PPA-DED process, as well as the influence of plasma arc current on microstructure evolution and mechanical properties, have not been fully elucidated. In this study, a FeCrNi alloy coating with FCC phase was deposited successfully via PPA-DED. The macroscopic morphology, microstructure characteristics, and mechanical properties of the FeCrNi alloy coating samples were explored systematically. The results indicated that the FeCrNi alloy coating has an excellent metallurgical bond with the 12Cr2Mo1R steel substrate, free of defects such as pores and cracks. The maximum alloy coating layer thickness of 1.42&#xa0;mm was achieved with a plasma arc current of 155&#xa0;A. The process of PPA-DED technology notably heightened the grain size and microhardness, particularly as the plasma arc current increased, which can be attributed to the rapid solidification process. The grain size increased from 9.7 to 10.3&#xa0;μm. The most noteworthy microhardness measurement of 206 HV was recorded at current of 155&#xa0;A. Additionally, as the current increased, the wear volume decreased from 0.78 to 0.45 mm<sup>3</sup>. The present work enhances the understanding of how arc current influences microstructure evolution and mechanical properties in PPA-DED processes.</p>

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Correlation Between Arc Current Value, Microstructure Evolution, and Mechanical Properties of the FeCrNi Alloy Coating Deposited via Powder Plasma Arc

  • 期刊论文

  • 发表日期：

    2026年4月17日

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  • Ta Jinguo,
  • Wang Shuai,
  • Li Gang,
  • Xue Cheng

摘要

Powder plasma arc directed energy deposited (PPA-DED) has emerged as a promising technique for the fabrication of multi-component alloy coatings. However, the thermal cycling characteristics inherent to the PPA-DED process, as well as the influence of plasma arc current on microstructure evolution and mechanical properties, have not been fully elucidated. In this study, a FeCrNi alloy coating with FCC phase was deposited successfully via PPA-DED. The macroscopic morphology, microstructure characteristics, and mechanical properties of the FeCrNi alloy coating samples were explored systematically. The results indicated that the FeCrNi alloy coating has an excellent metallurgical bond with the 12Cr2Mo1R steel substrate, free of defects such as pores and cracks. The maximum alloy coating layer thickness of 1.42 mm was achieved with a plasma arc current of 155 A. The process of PPA-DED technology notably heightened the grain size and microhardness, particularly as the plasma arc current increased, which can be attributed to the rapid solidification process. The grain size increased from 9.7 to 10.3 μm. The most noteworthy microhardness measurement of 206 HV was recorded at current of 155 A. Additionally, as the current increased, the wear volume decreased from 0.78 to 0.45 mm3. The present work enhances the understanding of how arc current influences microstructure evolution and mechanical properties in PPA-DED processes.