Structure-Phase State, Mechanical Properties, and Corrosion Behavior of Quasicrystalline AlCuFeSc Coating

Protection of AA2024 alloy against wear and corrosion by HVAF sprayed AlCuFe coating

“…The coating fractures occurred without any signs of detachment from the substrate for both the as-coated and annealed conditions. Thus, similarly to [39,45], the registered pull-off strength values relate to the cohesion between the powder particles forming the tested AlCuFe coatings, and the adhesion strength (bonding strength) magnitudes are higher. The bonding strength between the AlCuFe coating layer and the steel substrate was reported to be ∼26.4 ± 1.3 MPa regardless of the spraying parameters [21].…”

“…One of the most effective methods for the formation of protective coatings is high-velocity air or oxygen fuel spraying (HVAF, HVOF) [3,28,[36][37][38][39]. This technique allows controlling the temperature and thus the phase composition of the sprayed powders and obtained coatings.…”

“…This feature is very important for the materials of either metastable or limitedly stable nature, such as quasicrystals. Thus, a high-velocity air-fuel (HVAF) technique can be considered as a prospective method to avoid remelting or overheating the QC powder and, thus, to prevent the quasicrystal decomposition during the QC coating production process [37,39,40]. However, the ratio of the main elements and various additive elements can affect the stability and properties of the QC phase in different ways [3,22,23,39,41].…”

“…Thus, a high-velocity air-fuel (HVAF) technique can be considered as a prospective method to avoid remelting or overheating the QC powder and, thus, to prevent the quasicrystal decomposition during the QC coating production process [37,39,40]. However, the ratio of the main elements and various additive elements can affect the stability and properties of the QC phase in different ways [3,22,23,39,41]. Thus, the Si or Sn addition to the spray-formed Al-Cu-Fe quasicrystalline coatings resulted in its multi-phase structure which is deteriorative concerning anti-corrosion resistance [3,24,41].…”

“…Thus, the Si or Sn addition to the spray-formed Al-Cu-Fe quasicrystalline coatings resulted in its multi-phase structure which is deteriorative concerning anti-corrosion resistance [3,24,41]. Conversely, the addition of the Sc element was shown to promote the single QC phase state and the enhanced corrosion resistance of the AlCuFeSc coating [39,42]. Currently, mainly gas-atomized AlCuFe powders are used for the coating production [19,20,28,38].…”