Fe–Si–Al Coatings with Stable Wear Resistance Prepared by Laser Cladding Industrial Wastes

Abstract

Because wear is one of the most common reasons for the failure of metals, the development of a low-cost coating with enhanced wear resistance is of great importance. In the present study, Fe–Si–Al coatings with superior and stable wear resistance were prepared by laser cladding Fe–Si–Al industrial waste onto 1045 carbon steel. The microstructure, as well as the wear mechanism of the Fe–Si–Al coatings, was investigated. The Fe–Si–Al coatings consist of a (Al, Fe, Si) solid solution phase in both columnar grain form and equiaxed grain form. The Fe–Si–Al coatings possess enhanced microhardness of 494 ± 15 HV0.3 and low mass loss of 5 × 10−5 mg·(N·m)−1. The wear resistance is ten times higher than that of the 1045 carbon steel matrix. The wear of the Fe–Si–Al coatings is mainly dominated by abrasive wear and adhesive wear. This work provides important insight into the preparation of low-cost, wear-resistant coatings, as well as stable, superior wear resistance.

Additive Layer Manufacturing using Metal Deposition

“…Laser metal deposition is a well known efficient method for improving wear resistance, and more widely the lifetime, of metalic materials. The main novelty of Liu et al's work [2,3] is to use nonspherical powders coming from industrial Fe-Si-Al ribbons leftovers, thus reducing the cost of raw materials and of the global process. Through the deposition of a 2 mm thick coating on a 1045 carbon steel, significant improvements of the wear resistance (factor 10 reduction of mass loss) are demonstrated, coming from the high hardness deposit, and surprisingly with a rather low influence of (P,V) process parameters.…”