Thermally sprayed Fe-based coatings can be applied in conditions ranging from almost solid to complete molten droplets. While spraying under atmospheric conditions, the oxygen content in the coating varies depending on the spray parameters and the portion of molten phases in the droplets. Using vacuum-plasma technology, Fe-based alloys can be sprayed with a significant amount of molten phase without oxidation. This capability can also be used for alloying Fe-based sprays with nitrogen as is done during reactive vacuum plasma spraying. Such alloying promotes the formation of dispersed vanadium-nitride which greatly improves corrosion and wear resistance.

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