Evaluation of thermal shock failure mechanism of arc-sprayed Fe-based coatings deposited on different substrates

Weak bonding between coatings and substrates can result in the failure of components subjected to high-temperature fatigue leading to substantial economic losses and lower production efficiency. Coating spalling is typical in applications where large alternating thermal cycles are present. Thus, tight bonding between coating and substrate is critical to avoid thermal failure at high temperatures. A wide range of structural parts, machine equipment and boilers in power plants are made of ASTM A238C (Q235 steel equivalent) due to its intrinsic plasticity, weldability and low cost. The high toughness of 65Mn steel makes it suitable for applications such as rotary tiller blades for agricultural machinery, friction clutches and brakes for large engineering machinery. Therefore, applying appropriate surface coatings is essential for preventing thermal shock-induced damage and providing a barrier that minimizes thermal stress.

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