The effects of substrate dilution on the microstructure and wear resistance of PTA Cu-Al-Fe aluminium bronze coatings

Cu-Al-Fe aluminium bronze alloys are good candidates for precious tools and forming dies due to their high wear resistance, good sliding properties and low tendency for adhesion to ferrous metals. Plasma transferred arc (PTA) is an effective process for deposition of such robust coatings by enhancing the bond between the bronze coating and steel substrate. However, the microstructure and wear characteristics of these coatings are strongly influenced by the diffusion of substrate elements (mostly iron) to the interface. In the present study, the effects of substrate dilution on the microstructure and wear behaviour of Cu-Al-Fe alloy deposited by PTA on medium carbon steel substrate were investigated. The results show that the deposition current controls the melting temperature and iron dilution which result in the formation of Cu3Al martensitic β1' phase in a low dilution and the ordered β1 phase in high dilution. The wear behaviour of the coating is dominated by failure of the matrix phase. Low dilution coating with martensitic phase exhibits the highest wear resistance. On high diluted Fe rich coating, pile up of dislocation on the intermetallic K phase leads to surface cracks and delamination of the coating resulting in a high wear rate. •Plasma transferred arc current controlling the iron dilution of Cu-Al-Fe aluminium bronze coatings.•Martensitic phase formed at low arc current and iron intermetallics by high arc currents.•Coating with a martensitic phase has finer submicron structures and lowest specific wear rate.