Fabrication of FeSiB magnetic coatings with improved saturation magnetization by plasma spray and dry-ice blasting

Dry-ice blasting is applied in atmospheric plasma spraying process with an aim to deposit FeSiB magnetic coatings with improved saturation magnetization. Surface morphology, cross-sectional microstructure, phase composition, magnetic and mechanical properties of plasma-sprayed FeSiB coatings without and with the treatment of dry-ice blasting were compared with those deposited with compressed air cooling. The results indicate that dry-ice blasting has a significant effect on the surface morphology and cross-sectional microstructure of FeSiB coating. After the treatment of dry-ice blasting, the splashes and oxides of FeSiB coating drastically decreases and the Fe0.9Si0.1 phase of the coating decreases while the Fe2B increases due to the efficient cooling effect. In addition, a noticeable improvement in the saturation magnetization and in mechanical properties has been obtained, corresponding to the structural and composition changes.