Kinetic sprayed rare earth iron alloy composite coatings

One unique advantage of the kinetic spray process is its ability to mix constituents that would normally react with each other to form coatings. This attribute was used to produce composite coatings with different rare earth iron alloys (REFe2) and several ductile matrices. Composite coatings of Terfenol-D [(Tb0.3Dy0.7)Fe1.9] and SmFe2 were combined with ductile matrices of aluminum, copper, iron, and molybdenum. Evidence of an induced magnetic coercivity was measured for the REFe2-Mo and Fe composite coatings. Coatings were produced on flat substrates and shafts. Coating morphology as well as the physical, magnetostrictive, and magnetic properties of these coatings are discussed.