In situ nanostructured ceramic matrix composite coating prepared by reactive plasma spraying micro-sized Al–Fe2O3 composite powders

In situ nanostructured ceramic matrix composite coating was prepared by reactive plasma spraying micro-sized Al–Fe2O3 composite powders. The microstructure of the composite coating was characterized by X-ray diffraction, scanning electron microscopy and transmission electron microscopy, respectively. The results indicated that the composite coating exhibited dense and crack-free microstructure with a number of spherical α-Fe and γ-Al2O3 nano-grains embedded within equiaxed and columnar FeAl2O4 nano-grains matrix. The composite coating showed markedly higher toughness and wear resistance than the conventional Al2O3 coating.

Research highlights▶ In situ nanostructured ceramic matrix composite coating toughened by metallic phase can be successfully prepared by reactive plasma spraying micro-sized Al–Fe2O3 composite powders. ▶ The composite coating exhibits dense and crack-free microstructure with a number of spherical α-Fe and γ-Al2O3 nanosized grains embedded within the equiaxed and elongated FeAl2O4 nano-grains matrix. ▶ The composite coating shows considerably enhanced toughness and wear resistance compared with the conventional Al2O3 coating.