Plasma Sprayed Wear-Resistant, Low-Friction and Non-Stick Quasicrystalline (QC) Al-Cu-Fe Coatings

Quasicrystalline (QC) materials, first discovered in the early 1980s, are known to provide a unique combination of physical and mechanical properties. Among them, ternary Al-Cu-Fe alloys are most interesting due to their favorable properties at low cost. The combination of thermal spraying and subsequent grinding represents a promising approach for the production of customized QC surfaces. However, the inherent brittleness and complex phase composition of these materials pose a major challenge for both processes. The aim of this study was to develop and to optimize Al-Cu-Fe coatings that are smooth, wear-resistant, low-friction and non-stick. For this purpose, a novel, industrially scalable powder was plasma sprayed. The coatings were post-treated using a reciprocating grinding process to adapt the surface properties. Characterizations were performed with regard to tribomechanical, microstructural, topographical and non-stick properties. In addition, correlations with the process parameters were developed.