Fundamental Investigation of Application Possibility of Fe-based Coatings for Thermal Insulation

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The low thermal conductivities (<3 W/mK) and relatively high thermal expansion coefficients (>14*10-6 K-1) of Fe-based amorphous coatings such as Fe25Cr8Mo10W-5Mn5B2C2Si provide a possibility to apply such Fe-based amorphous coatings for thermal insulation up to 400 °C, below which Al-alloys are used. Up to now, this possibility has hardly been investigated. The purpose of this application is to investigate fundamentally the possibility of using Fe-based amorphous coatings for thermal isolation of Al parts. To achieve the purpose, new Fe-based spray materials are produced and characterized. These new powders are sprayed thermally by atmospheric plasma spraying and HVOF-spraying in comparison to Fe25Cr8Mo10W5Mn5B2C2Si as reference. The influence of spray materials, processes and parameters on phase composition and microstructure, thus on thermo-physical properties like thermal conductivity, expansion coefficient and crystallization temperature of amorphous phases will be systematically studied. The oxidation resistance, thermal stability and thermo-shock behavior of these Fe-based coatings will be evaluated using different furnace tests.