Kinetic sprayed rare earth iron alloy composite coatings

One unique advantage of the kinetic spray process is its ability to mix constituents that would normally react with each other to form coatings. This attribute was used to produce composite coatings with different rare earth iron alloys (REFe₂) and several ductile matrices. Composite coatings of Terfenol-D (Tb_0.3Dy_0.7)Fe_1.9] and SmFe₂ were combined with ductile matrices of aluminum, copper, iron, and molybdenum. Evidence of an induced magnetic coercivity was measured for the REFe₂-Mo and Fe composite coatings. Coatings were produced on flat substrates and shafts. Coating morphology as well as the physical, magnetostrictive, and magnetic properties of these coatings are discussed. This article was originally published inBuilding on 100 Years of Success: Proceedings of the 2006 International Thermal Spray Conference (Seattle, WA), May 15–18, 2006, B.R. Marple, M.M. Hyland, Y.-Ch. Lau, R.S. Lima, and J. Voyer, Ed., ASM International, Materials Park, OH, 2006.