Comparison of Microstructures and Selected Properties of Plasma-Sprayed Iron-Based Metallic Glass Coatings

The three powders (Fe0.9Co0.1)76Mo4(P0.45C0.2B0.2Si0.15)20, Fe48Mo14Cr15Y2C15B6, and Fe56.04Co13.45Nb5.5B25 were produced by gas atomization and sieved to the fraction of + 15 to 50 µm. The chemical compositions of the powders were selected to cover three groups of iron-based metallic glass alloys, which were separated in terms of non-metal elements: B, C, and P included in these alloys. The powder morphology and size distribution were determined. The coatings were then prepared on steel substrates with atmospheric plasma spraying. The coating microstructures were characterized by light microscopy, scanning electron microscopy, and their phase compositions were confirmed by XRD. Additionally, the hardness and Young's moduli were studied with nanoindentation. The bond strength of the coatings was determined by a pull-off test. Finally, the wear properties were evaluated with the rubber wheel test according to the ASTM G65-04 standard. For the Fe48Mo14Cr15Y2C15B6 coatings, it was possible to preserve the fully amorphous structure, and these coatings were characterized by the lowest wear loss values.