Deposition and Characterization of Thermally Sprayed Coatings Prepared by a Nanostructured Martensitic Steel Powder

This work introduces thermal spraying of an agglomerated high energy ball milled powder produced by a commercial, martensitic steel. The nanostructure of the powder feedstock was examined by means of Scanning Electron Microscopy (SEM) and X-Ray Diffraction (XRD). Varying levels of HVOF process spraying parameters were employed to deposit the nanostructured feedstock. After coating deposition, the influence of different parameters on crucial coating properties, such as nanostructure retention, porosity, microhardness, adhesion, wear resistance and high temperature oxidation resistance, was studied. The coating performance on these properties was found to be affected by the state of the deposited particles which were related to the spraying parameters.