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Microstructure and wear behavior of quasicrystalline thermal sprayed
An Al-Cu-Fe alloy coating which forms a quasicrystalline phase is a potential candidate for replacing electro-deposited chromium on various components in the Space Shuttle Main Engine. Coatings were deposited by air and vacuum plasma spraying and by high-velocity oxygen-fuel spraying. Finer starting powders tended to lose Al during spraying, which affected the phase equilibrium of the coatings. Coatings which retained the starting powder composition were richer in the desired quasicrystalline phase. Ball-on-disk wear tests between 440 C stainless steel ball and the Al-Cu-Fe coatings were performed. Coefficients of friction ranged from 0.60 to 1.2 for the different coatings