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In this study, zinc-aluminum alloy coatings were deposited on low carbon steel substrates by arc thermal spraying with different current and spraying distances. Optical microscope (OM) was used to characterize the deposited coatings. From the experiment, it is found that the samples that use different electric currents and spraying distances result in the different microstructure of the coating surfaces and different mechanical properties. The sample that uses higher current tends to have a higher hardness than the sample with a lower electric current at the same spraying distance.

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ABSTRACT

Iron (Fe)-tin (Sn) intermetallics were synthesized by using two different routes. These two routes had a common synthesis step, in which Fe powder (19 wt. %) was mechanically alloyed with Sn powder (81 wt. %) for 25 h under argon atmosphere. The mechanically alloyed powders were then treated with different heating routes. In the first route, the compacts of the mechanically alloyed powders were sintered at different temperatures for different times. It was found that the FeSn2 content increased with increasing temperature and time. There were small traces of Fe, Sn and FeSn found in the sintered materials. In the second route, the mechanically alloyed powders were plasma-sprayed using different currents of 300, 400 and 500 A. It was found that the porous coatings produced by plasma sprayng consisted of mixed Fe, Sn, FeSn2, SnO, FeO and Fe3O4 for all employed currents.