Microstructure and magnetic properties of plasma-sprayed Fe73.5Cu1Nb3Si13.5B9 coatings

Amorphous and nanocrystalline Fe73.5Cu1Nb3Si13.5B9 coatings were formed by plasma-spraying micron-sized powders onto H62 brass substrates and aluminum pipes. The coatings are about 0.2-0.3 mm in thickness with fully dense and low porosity. The microstructure of the coatings is classified into two regions, namely, a full amorphous phase region and homogeneous dispersion of α-Fe nanoscale particles with a scale of 30-70 nm. The hardness of the amorphous and nanocrystalline coatings is about 960 HV100g. Coercivity (Hc), saturation induction (B800), and initial relative permeability (μi) of the coatings are 144 A/m, 0.27 T, 249, respectively, under 800 A/m direct current (DC) magnetic field. The magnetic shielding performance is good under DC magnetic field and its magnetic shielding effectiveness (SE) is 10-12 dB at coating thickness of 0.45 mm under static magnetic field of 2-40 Oe. The SE increases by increasing the coating thickness when the magnetic field frequencies are 50, 100 and 200 Hz with an intensity of 0.85 Oe. The results indicate that the amorphous and nanocrystalline alloy coatings can be good for some magnetic shielding applications.