Fe-B composite powder was produced by spray-drying of elemental iron and boron powders. Fe-ZrB2 composite powder was made by ball-milling of elemental iron and ZrB2 powders. These powders were plasma-sprayed in low-pressure argon atmosphere to produce iron matrix composite deposits with dispersed boride particles. As-sprayed deposits formed using Fe-B composite powder are composed of ferrite (α) and austenite (γ) phase that is supersaturated with boron due to the high cooling rate of molten particles on a substrate. Heat treatment of the deposit at 673 K leads to the formation of Fe3B. The deposit heat-treated at 1073 K is made up of α, Fe2B, and FeB. With increasing heat-treatment temperature up to 1073 K, the hardness of the deposit decreases. As-sprayed deposit produced using Fe-ZrB2 composite powder is composed of α, ZrB2, Fe2B, and Fe3Zr. Heat treatment of the deposit at 1073 K results in the formation of FeB. Heat treatment at 1073 K lowers hardness of the deposit.

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