Study of High-Temperature Abrasive Wear Behavior of Shrouded-Plasma-Sprayed FeAl and FeAl/TiC Composite Coatings

FeAl intermetallic compound matrix composites reinforced by ceramics particles are potential candidates for the protection of materials used in high temperature conditions. In this study, shrouded plasma spraying with nitrogen as a protective gas was employed to prepare FeAl and FeAl/TiC composite coatings using ball milled Fe-35Al and Fe-35Al/TiC composite powders which contained 35 vol.% and 45 vol.% TiC. The high-temperature abrasive wear behavior of the as-sprayed FeAl and FeAl/TiC coatings at 400^oC, 600^oC, and 800^oC was investigated. The results showed that dense FeAl and FeAl/TiC coatings with low oxide inclusions were deposited by shrouded plasma spraying. FeAl coating showed a high abrasive wear loss, while the addition of TiC particles to FeAl matrix lead to an improvement in its wear resistance. The abrasive wear resistance of the as-sprayed FeAl/TiC coatings increased with increasing TiC content. The wear mechanisms of the coatings at high temperature were examined.