The effect of spray forming on the microstructure and properties of a high chromium white cast iron

The effect of spray forming on the structure and properties of a 17% Cr, 2.5% C white cast iron is described and compared with conventionally cast material of the same composition. Spray forming resulted in a substantial reduction in microstructural scale (eutectic (Cr,Fe)(7)C-3 fields of up to 500 mu m in conventionally cast material were replaced by discrete carbides of typically 2-8 mu m diameter in the spray cast deposit). Carbide size varied as a function of position in the spray deposit, being approximately twice the size at mid section compared with either surface or interface with the collector. Carbide size was not altered by the gas to metal ratio used to atomise the spray. Spray forming increased transverse rupture stress and work of fracture by similar to 50% compared with the conventionally cast material. Forging of the spray formed material was possible at similar to 950 degrees C, without inducing carbide fracture or void formation in the matrix. Quenching into iced water from 300 degrees C induced extensive macroscopic cracking in the conventionally cast material whereas 400 degrees C was required in the spray cast material to induce similar damage. The relationship between processing, microstructure and mechanical properties is discussed. (C) 1999 Kluwer Academic Publishers.