Particle Size-Dependent Microstructure, Hardness and Electrochemical Corrosion Behavior of Atmospheric Plasma Sprayed NiCrBSi Coatings

Particle size is a critical consideration for many powder coating-related industries since it significantly influences the properties of the produced materials. However, the effect of particle size on the characteristics of plasma sprayed NiCrBSi coatings is not well understood. This work investigates the microstructures, hardness and electrochemical corrosion behavior of plasma sprayed NiCrBSi coatings synthesized using different-sized powders. All coatings mainly consist of Ni, N3B, CrB, Cr7C3 and Cr3C2 phases. The coatings produced by small particles (50-75 mu m) exhibit lower porosity (2.0 +/- 0.8%). Such coatings show a higher fraction (15.5 vol.%) of the amorphous phase and lower hardness (700 HV0.5) than the counterparts (8.7 vol.% and 760 HV0.5, respectively) produced by large particles (75-100 mu m) with higher porosity (3.0 +/- 1.6%). Meanwhile, the coatings produced from smaller particles possess a larger number of non-bonded boundaries, leading to the easier penetration of corrosive medium, as well as a higher corrosion current density (0.254 +/- 0.062 mu A/cm(2)) and a lower charge transfer resistance (0.37 +/- 0.07 M Omega cm(2)). These distinctions are attributed to particle size-induced different melting degrees and stackings of in-flight particles during deposition.