Mechanical and Physical Properties of HVOF-Sprayed Iron Aluminide Coatings

Tensile tests and thermal-expansion measurements were performed on free-standing, high-velocity oxy-fuel (HVOF) sprayed Fe3Al coatings produced at spray-particle velocities of 390, 560, and 620 m/s. To examine the relationship between properties and spray conditions, the microstructures of the coati...

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Bibliographic Details
Published in:Metallurgical and materials transactions. A, Physical metallurgy and materials science Physical metallurgy and materials science, 2003-10, Vol.34 (10)
Main Authors: Totemeier, Terry Craig, Wright, Richard Neil, Swank, William David
Format: Article
Language:English
Subjects:
BONDING
COATINGS
DEFECTS
DISLOCATIONS
FRACTURE PROPERTIES
GENERAL AND MISCELLANEOUS//MATHEMATICS, COMPUTING, AND INFORMATION SCIENCE
high-velocity oxy-fuel
IRON
LINE BROADENING
OXIDES
PHYSICAL PROPERTIES
POROSITY
STRESSES
tensile tests
THERMAL EXPANSION
THICKNESS
VELOCITY
X-RAY DIFFRACTION
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Summary:Tensile tests and thermal-expansion measurements were performed on free-standing, high-velocity oxy-fuel (HVOF) sprayed Fe3Al coatings produced at spray-particle velocities of 390, 560, and 620 m/s. To examine the relationship between properties and spray conditions, the microstructures of the coatings were characterized in terms of the fractions of unmelted particles, porosity, and oxide inclusions, as well as the dislocation density assessed by X-ray diffraction (XRD) line-broadening analysis. Residual coating stresses were determined as a function of coating thickness using curvature measurements. The tensile behavior was entirely brittle at room temperature; fracture strengths increased with spray-particle velocity; and the increase in fracture-strength results from decreasing fractions of microstructural defects and better interparticle bonding. The mean thermal-expansion coefficients for the coatings were lower than those for an equivalent wrought material; the differences were attributed to a 7 to 15 vol pct fraction of oxide inclusions.
ISSN:1073-5623
1543-1940
DOI:10.1007/s11661-003-0286-7