Influence of the wire diameter and particle fraction of Fe-Al2O3/ZrO2 flux-cored wires processed by wire arc spraying on the abrasive wear properties of the coating

The embedding of ceramic particles of a certain size and concentration in a ductile matrix is a strategy for producing wear-resistant coatings. In wire arc spraying, flux-cored wires with a metallic sheath and particle-filled core can be used for this purpose. The influence on wear properties of wire diameter and particle fraction has hardly been investigated so far. Due to the high kinetics of arc and gas flow, there are considerable challenges with regard to reproducibility, homogeneity and material efficiency. As a basis for a significantly improved understanding of the process, the relationships between the wire diameter, the particle fraction used and the wear resistance of the produced coatings have been investigated. The objects of investigation were flux-cored wires with an iron sheath and a particle filling of Al2O3/ZrO2. By using the ball-on-disc test and rubber wheel test, the wear resistance of the respective coatings was investigated.