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The fabrication of an alumina-metal composite coating onto a carbon steel substrate by using a self-propagating high-temperature synthesis technique was demonstrated. The effects of the type and thickness of the pre-coated layer on the binding structure and surface quality of the coating were systematically investigated. The macrostructure, phase composition, and bonding interface between the coating and the substrate were investigated by scanning electronic microscopy (SEM), X-ray diffraction (XRD), and energy-dispersive X-ray spectrometry (EDS). The diffraction patterns indicated that the coating essentially consisted of α-AlO, Fe(Cr), and FeO·AlO. With an increase in the thickness of the pre-coated working layer, the coating became more smooth and compact. The transition layer played an important role in enhancing the binding between the coating and the substrate. When the pre-coated working layer was 10 mm and the pre-coated transition layer was 1 mm, a compact structure and metallurgical bonding with the substrate were obtained. Thermal shock test results indicated that the ceramic coating exhibited good thermal shock resistance when the sample was rapidly quenched from 800°C to room temperature by plunging into water. [ABSTRACT FROM AUTHOR]

AlO-metal composite coatings with different reactants and diluents were fabricated on mild steel plate with nonpressure combustion synthesis process. The coatings were characterized by means of X-ray diffraction, scanning electron microscopy, and energy-dispersive spectrometry, respectively. Thermal shock tests were carried out to determine the bond strength of the coating with the steel substrate. The results indicate that the coating is composed of α-AlO, α-(Fe-Cr) and AlSiO as the main phases. It is found that the coating with the diluents of AlO-SiO and transition layer of AlO-Cr presents the highest hardness of 2270 HV0.2 and the lowest porosity of 3.93 %. Owing to a metallurgical bond of the coating-to-substrate, the coating exhibits a good thermal shock resistance. [ABSTRACT FROM AUTHOR]