Load-dependent wear behavior of novel Fe-based amorphous APS coating derived from compositionally modified high-P pig iron

This study examines the wear resistance of a new amorphous coating fabricated by APS thermal spraying using industrial grade pig iron. The coating 's performance is evaluated under varying plasma power conditions at three distinct loads of 40, 50, and 60 N. Scanning electron microscope (SEM) micrographs are analyzed to measure the porosity and thickness of each coating. The average porosities (%) of S1-S4 and S5-S8 coatings are 07 +/- 03 and 14 +/- 04, respectively. The rates of wear between reference mild steel and among all coatings at three different loads are evaluated, compared, and correlated with plasma powers to arrive at optimal level of plasma power. The plasma power of 30 -35 kW corresponding to the least wear rate is found to be optimal at three different loads. Further, the generated debris particles are subjected to morphological and phase analysis by scanning electron microscopy and Fourier-transformed infrared spectroscopy. Detailed microstructural analysis of worn surfaces indicates that the wear modes include delamination, abrasion, and oxidation