Nanostructured ceramic composite coating prepared by reactive plasma spraying micro-sized Al–Fe2O3 composite powders

Nanostructured ceramic matrix composite coating was prepared in-situ by reactive plasma spraying micro-sized Al-Fe2O3 composite powders. The microstructure, toughness and Vickers hardness of these coatings were investigated by X-ray diffraction, scanning electron microscopy, transmission electron microscopy and mechanical tests. The results indicated that the coating exhibited nanostructures which consisted of FeAl2O4, Al2O3, Fe (or Fe solid solution) and a little FeAl. The composite coating showed significantly higher toughness and wear resistance than the conventional Al2O3 coating.