Comparison of microstructure and mechanical properties of Fe3Al/TiC coatings produced by cold gas spray and high velocity oxygen fuel

Fe 3 Al powders reinforced with TiC were synthesized and deposited as coatings using Cold Gas Spraying (CGS) and High-Velocity Oxy-Fuel (HVOF) techniques. Fe 3 Al intermetallic compounds are known for their excellent resistance to sulfidizing and carburizing environments. However, their mechanical properties can be enhanced through reinforcement with TiC particles. The Fe 3 Al/TiC feedstock powder was produced via agglomeration and sintering, resulting in a homogeneous distribution of TiC particles around the Fe 3 Al matrix. Coatings were deposited onto AISI 316L stainless steel substrates and characterized using X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), Energy-Dispersive X-ray Spectroscopy (EDX), as well as adhesion and erosion tests. The results indicate that CGS coatings exhibit lower oxidation levels, whereas HVOF coatings demonstrate superior adhesion and hardness due to their denser microstructure and greater particle deformation. Hardness increased with the incorporation of TiC. Erosion testing revealed that CGS coatings performed better, attributed to their reduced brittleness compared to HVOF coatings. These findings highlight the potential of Fe 3 Al/TiC coatings for high-temperature and wear-resistant applications. Moreover, the study demonstrates that comparable performance can be achieved using CGS as with HVOF for depositing Fe 3 Al/TiC intermetallic coatings. • A new Fe 3 Al/TiC powder was produced by agglomeration and sintering. • CGS proven as a viable HVOF alternative for Fe 3 Al/TiC high-wear coatings. • TiC boosts Fe 3 Al hardness; HVOF excels in hardness, CGS in erosion resistance. • In CGS, He carrier gas beats N 2 , yielding higher hardness and adhesion.