Studies on composite coatings prepared by plasma spraying Fe2O3–Al self-reaction composite powders

Fe2O3–Al composite powders were prepared using ferric oxide agent powders, aluminum powders and polyvinyl alcohol. Self-reaction composite coatings containing ceramic and metal multi-phases were fabricated by plasma spraying Fe2O3–Al composite powders. This technology successfully combines self-propagating high-temperature synthesis with plasma spraying. The morphology of the composite powders was examined by scanning electron microscope (SEM). The chemical composition, microstructure, Vickers hardness, density, porosity and wear resistance of the composite coating were studied. The wear resistance of the ceramic and metal multi-phase composite coating was significantly improved under heavy load.