Influence of Ni, Al, W doping on microstructure, corrosion and wear resistance of HVOF spraying Fe-based amorphous alloy coatings
A series of novel Fe-based amorphous alloy coatings (AACs) with outstanding corrosion and wear resistance, composed of Fe57Cr15Mo4P10C7B3M4 (M = Fe, Ni, Al and W, in at. %) with various alloying elements, were fabricated using high-velocity oxygen fuel (HVOF) technique. The effect of Ni, Al, and W o...
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Elsevier
2025-03-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425000663 |
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| author | Chengwu Zhang Lei Xie Qiang Li Guan Zhang Chuntao Chang Hongxiang Li Xu Ma Lin Liu |
| author_facet | Chengwu Zhang Lei Xie Qiang Li Guan Zhang Chuntao Chang Hongxiang Li Xu Ma Lin Liu |
| author_sort | Chengwu Zhang |
| collection | DOAJ |
| description | A series of novel Fe-based amorphous alloy coatings (AACs) with outstanding corrosion and wear resistance, composed of Fe57Cr15Mo4P10C7B3M4 (M = Fe, Ni, Al and W, in at. %) with various alloying elements, were fabricated using high-velocity oxygen fuel (HVOF) technique. The effect of Ni, Al, and W on microstructure, thermal behavior, corrosion resistance, and wear resistance of these fabricated Fe-based AACs were investigated systematically compared to 316L stainless steel (316L SS) substrates. Microstructural analysis revealed that the present Fe-based AACs exhibited a dense and uniform microstructure with high thermal stability. Electrochemical test results demonstrated that doping with Ni, Al and W significantly enhanced the corrosion resistance of the base alloy AAC. The W-doped AAC showed the best performance than Ni-doped, Al-doped and base alloy AAC, with a wide passive region (ΔEpass) of 1.7 V, low self-corrosion current density (Icorr) of 1.07 × 10−6 A·cm−2 and the lowest steady-state current densities and highest passivation index. Mott–Schottky analysis and X-ray photoelectron spectroscopy results showed that the W-doped AACs forming the densest and thickest passivation films, ascribed to an increased fraction of protective and stable low-valent metal oxides (Fe2+/Cr3+/Mo4+), enhanced corrosion resistance by promoting film growth and degradation processes. Dry wear tests revealed that among these Fe-based AACs, the W-doped AAC exhibited the superior wear resistance, with the lowest coefficient of friction (0.42) and wear rate (2.8 × 10−5 mm3·N−1·m−1), because of higher amorphous content and higher hardness. Under wear conditions, the primary wear mechanisms identified for the Fe-based AACs were abrasive, fatigue, and oxidative wear. |
| format | Article |
| id | doaj-art-d9166dc0ddb64e6f96804dce8bfa6462 |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | Elsevier |
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| series | Journal of Materials Research and Technology |
| spelling | doaj-art-d9166dc0ddb64e6f96804dce8bfa64622025-01-18T05:04:44ZengElsevierJournal of Materials Research and Technology2238-78542025-03-013510101029Influence of Ni, Al, W doping on microstructure, corrosion and wear resistance of HVOF spraying Fe-based amorphous alloy coatingsChengwu Zhang0Lei Xie1Qiang Li2Guan Zhang3Chuntao Chang4Hongxiang Li5Xu Ma6Lin Liu7School of Physics Science and Technology, Xinjiang University, Urumqi, Xinjiang, 830046, PR ChinaSchool of Materials Science and Engineering, Xinjiang University, Urumqi, Xinjiang, 830046, PR China; Xinjiang Environmental Functional Materials Engineering Technology Research Center, Xinjiang University, Urumqi, Xinjiang, 830017, PR ChinaSchool of Materials Science and Engineering, Xinjiang University, Urumqi, Xinjiang, 830046, PR China; Xinjiang Environmental Functional Materials Engineering Technology Research Center, Xinjiang University, Urumqi, Xinjiang, 830017, PR China; Corresponding author. School of Materials Science and Engineering, Xinjiang University, Urumqi, Xinjiang, 830046, PR China.qli@xju.edu.cnSchool of Materials Science and Engineering, Xinjiang University, Urumqi, Xinjiang, 830046, PR China; Xinjiang Environmental Functional Materials Engineering Technology Research Center, Xinjiang University, Urumqi, Xinjiang, 830017, PR ChinaSchool of Mechanical Engineering, Dongguan University of Technology, Dongguan, 523808, PR China; Corresponding author.State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Beijing, 100083, PR ChinaSchool of Physics Science and Technology, Xinjiang University, Urumqi, Xinjiang, 830046, PR ChinaSchool of Materials Science and Engineering, State Key Lab for Materials Processing and Die & Mold Technology, Huazhong University of Science and Technology, Wuhan, 430074, PR China; Corresponding author.A series of novel Fe-based amorphous alloy coatings (AACs) with outstanding corrosion and wear resistance, composed of Fe57Cr15Mo4P10C7B3M4 (M = Fe, Ni, Al and W, in at. %) with various alloying elements, were fabricated using high-velocity oxygen fuel (HVOF) technique. The effect of Ni, Al, and W on microstructure, thermal behavior, corrosion resistance, and wear resistance of these fabricated Fe-based AACs were investigated systematically compared to 316L stainless steel (316L SS) substrates. Microstructural analysis revealed that the present Fe-based AACs exhibited a dense and uniform microstructure with high thermal stability. Electrochemical test results demonstrated that doping with Ni, Al and W significantly enhanced the corrosion resistance of the base alloy AAC. The W-doped AAC showed the best performance than Ni-doped, Al-doped and base alloy AAC, with a wide passive region (ΔEpass) of 1.7 V, low self-corrosion current density (Icorr) of 1.07 × 10−6 A·cm−2 and the lowest steady-state current densities and highest passivation index. Mott–Schottky analysis and X-ray photoelectron spectroscopy results showed that the W-doped AACs forming the densest and thickest passivation films, ascribed to an increased fraction of protective and stable low-valent metal oxides (Fe2+/Cr3+/Mo4+), enhanced corrosion resistance by promoting film growth and degradation processes. Dry wear tests revealed that among these Fe-based AACs, the W-doped AAC exhibited the superior wear resistance, with the lowest coefficient of friction (0.42) and wear rate (2.8 × 10−5 mm3·N−1·m−1), because of higher amorphous content and higher hardness. Under wear conditions, the primary wear mechanisms identified for the Fe-based AACs were abrasive, fatigue, and oxidative wear.http://www.sciencedirect.com/science/article/pii/S2238785425000663Fe-based amorphous alloy coatingsMicroalloyingCorrosion resistancePassivation filmWear resistance |
| spellingShingle | Chengwu Zhang Lei Xie Qiang Li Guan Zhang Chuntao Chang Hongxiang Li Xu Ma Lin Liu Influence of Ni, Al, W doping on microstructure, corrosion and wear resistance of HVOF spraying Fe-based amorphous alloy coatings Journal of Materials Research and Technology Fe-based amorphous alloy coatings Microalloying Corrosion resistance Passivation film Wear resistance |
| title | Influence of Ni, Al, W doping on microstructure, corrosion and wear resistance of HVOF spraying Fe-based amorphous alloy coatings |
| title_full | Influence of Ni, Al, W doping on microstructure, corrosion and wear resistance of HVOF spraying Fe-based amorphous alloy coatings |
| title_fullStr | Influence of Ni, Al, W doping on microstructure, corrosion and wear resistance of HVOF spraying Fe-based amorphous alloy coatings |
| title_full_unstemmed | Influence of Ni, Al, W doping on microstructure, corrosion and wear resistance of HVOF spraying Fe-based amorphous alloy coatings |
| title_short | Influence of Ni, Al, W doping on microstructure, corrosion and wear resistance of HVOF spraying Fe-based amorphous alloy coatings |
| title_sort | influence of ni al w doping on microstructure corrosion and wear resistance of hvof spraying fe based amorphous alloy coatings |
| topic | Fe-based amorphous alloy coatings Microalloying Corrosion resistance Passivation film Wear resistance |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425000663 |
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