Tailoring the Mechanical, Tribological and Corrosion Behavior of Fe-Based Metallic Glass Coating Synthesized Using Atmospheric Plasma Spraying

Since the last few decades, plasma spraying has gained its reputation to produce excellent metallic glass coatings because of its high process controllability. Present work studies the effect of various plasma spray parameters on the mechanical, tribological and the corrosion properties of plasma sprayed Fe-based bulk metallic glass (BMG) coating. The in-flight particle velocity and temperature were monitored using the accuraspray diagnostic sensor. Among different sets of parameters, combination of higher power at lower feed rate and higher gas flow provided the maximum density of the coating due to better melting of the particles. XRD analysis showed that high-temperature exposure of the in-flight particles incepted few traces of oxides and carbides in the coating, apart from the intrinsic α- and γ-phases of the Fe-based feedstock. The corrosion resistance of the coatings was highly influenced by the stand-off distance, keeping all the other parameters at higher values. The reason may be attributed to the more number of powder particles melting at higher power and impinging on the substrates at quite lesser time. Current work concludes that the various properties of the Fe-based BMG coating are seriously tailored by different sets of plasma parameters that urge to govern the overall coating properties.