Effect of Fe content on wear resistance of thermal-sprayed Al–17Si–XFe alloy coating on A6063 Al alloy substrate

To improve the wear resistance of Al alloy, Al–17 mass% Si–X mass% Fe Al alloy powders with different Fe content from 5 to 30 mass% and Al–50 mass% Fe alloy powders were thermal-sprayed on Al alloy A6063 substrate by a low pressure plasma spraying. Microstructure and wear property of the coatings were evaluated. The most beneficial coating can be obtained with Al–17 mass% Si–10 to 15 mass% Fe alloy powders, showing good wear resistance, four times of the substrate and low friction coefficient, approximately 0.4 without cracking and peeling in the coating and the interface between the substrate.