Abstract
This study assesses the effect of different alloying elements on the microstructure, oxygen content, hardness, and corrosion resistance of stainless steel coatings produced by atmospheric plasma spraying. SUS836L stainless steel powder with Si, Mn, and B additions served as the base feedstock alloy to which different amounts of B, C, Mo, Ti, Nb, V, and Cu were added. The powder mixtures were sprayed on carbon steel substrates and the deposits were examined and tested. The results show that B and C additions of 2-3% have a beneficial effect, but at 5% cause a drop in corrosion resistance that proved to be remediable through the addition of Cu, which improves the corrosion potential of the matrix phase by its combined action with Mo, Si, and B. The effect of Ti, Nb, and V, which are added to suppress Cr oxidation in molten alloy particles during flight, is that it promotes that formation of fine carbide and boride compounds, increasing hardness without sacrificing corrosion resistance. In addition to these findings, the study also shows that the coatings developed are in many ways comparable to Ni-based self-fluxing alloy coatings.