Effect of Dry-Ice Blasting on Structure and Magnetic Properties of Plasma-Sprayed Fe-40Al Coating from Nanostructured Powders

Amorphous and nanocrystalline materials have attracted much interest in the field of new materials design because of their excellent mechanical and physical properties as well as their magnetic properties. In this work, Fe-40Al coatings were prepared from a nanostructured feedstock by atmospheric plasma spray combined with dry-ice blasting. The scanning electron microscopy, x-ray diffraction, tensile test, and magnetic measurements were used to investigate microstructure, phase structure, adhesion, and magnetic properties of the deposited coatings. The results showed that after using dry-ice blasting, the oxidation and porosity decreased and the atmospheric plasma-sprayed Fe-40Al coatings exhibited a soft ferromagnetic character with lower coercivity and higher saturation magnetization due to their lower degree of order. The plasma-sprayed Fe-40Al coating from the nanostructured feedstock has a very high adhesive strength.