Abstract
Different feedstock powder compositions of the alumina-chromia system were deposited on steel substrates by various methods, including conventional plasma spraying, three-anode plasma spraying, and HVOF. The powders used for plasma spraying had particle sizes of -38+10 µm and for HVOF spraying -25+5 µm and -25+10 µm. The coatings were evaluated by their microstructure, phase composition, and corrosion, wear, and electrical properties. The study shows that wear properties depend strongly on the spray process and that coatings obtained by HVOF spraying have dense structures and excellent wear behavior. Coatings produced by the three-anode plasma process, despite their higher porosity, were found to be harder than conventional plasma coatings and can be sprayed with higher feed rates. The coating properties do not appear to have a linear dependence on chromia content.
