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Microstructure and wear resistance of spray formed and conventionally cast high‐chromium white iron

A billet of hypoeutectic high‐chromium white iron (19% Cr, 2.5% C) was spray formed using Gas‐to‐Metal Ratios (GMR) of 0.9, 1.0, and 1.1. Microstructural studies and dry sand rubber wheel abrasion tests were carried out, on the one hand, to compare between the spray formed and conventionally cast material and, on the other hand, to investigate the relationship between gas‐to‐metal‐ratio, eutectic carbide morphology and abrasion resistance. The spray formed material was characterized by a considerably finer carbide morphology (max. ˜30 μm) than the conventionally cast material (max. 100–200 μm). The coarser carbide morphology is believed to be responsible for the superior abrasion resistance of the conventionally cast material. Although the carbide morphology of the spray formed material was only moderately influenced by the changes in the gas‐to‐metal‐ratio, there was a clear improvement in the abrasion resistance with decreasing gas‐to‐metal‐ratio. The improvement correlated with a decrease in the fraction of very fine (<1.5 μm) carbides, rather than with an increase in the mean carbide size.