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High velocity arc spraying (HVAS) was utilized to in-situ deposit a series of comprising TiB2 (0~70% TiB2/Al2O3 in cored powder) composite coating on soft steel substrate. The microstructure, phase characterization and properties of composite coatings were investigated. The results demonstrate that the microstructure and wear performance of composite coatings are influenced by metallurgical transformation during spraying process. As a consequence of non-equilibrium synthesis by HVAS processing, several phases such as TiB2, Al2O3, FexB, AlFe3 and NiAl in Fe matrix form. The anti-friction of composite coatings is improved with increasing ceramic phase content, and the friction mass loss follows a linear rule with ceramic phase volume fraction. TiB2 decomposition results in reduced hardness and wear resistance of the coatings. Coatings with Al, Ni show lower porosity and higher wear resistance. Thus, coatings of high wear resistance with TiB2 phase can be produced using high velocity arc spraying.
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