PLASMA ARC COATINGS PRODUCED FROM POWDER-CORED WIRES WITH STEEL SHEATHS

Abstract

Coatings produced from powder-cored wires developed at the Paton Electric Welding Institute that were plasma arc deposited onto a low-carbon steel substrate were characterized. Interaction between the steel sheath (constituting at least 80 wt.% of the wire) and powder cores, such as B₄C, B₄C + ZrO_2(nano), B₄C + (Cr, Fe)₇С₃, and B₄C + (Cr, Fe)₇С₃ + Al, in the arc plasma deposition process was analyzed. The resultant coatings were free of defects and had low porosity (to 2.5%) and lamellar structure. The core carbide components were found to dope the coating ferritic matrix and strengthen it with fine carbide, carboboride, and boride particles. An addition of 0.5% ZrO₂ nanopowder refined the coating structure and participated in the formation of fine Fe₂B and Fe₃B borides. An aluminum addition within 10 wt.% did not form iron aluminides but, being easily melted, activated the interaction between components, reduced porosity, and improved adhesion strength of the coatings. The coatings reach a microhardness of 6.25−8.59 GPa, being 4 to 5.5 times higher than the microhardness of the steel wire sheath. The development and use of such powder-cored wires expanded the application of plasma arc spraying, particularly for the protection of equipment against abrasive gas wear in chemical engineering, in the production of parts for pumps, compressors, and other components, and for the recovery of worn parts.