Development and Characterization of Natural Chromite Coating on Metal Substrate Using the Plasma Spray Process

[Image: see text] Natural materials are gaining interest as coating feedstock because their “quality to cost” ratio is better and they are more environmentally friendly than most of the synthetic ceramics. They give sufficient protection to metal surfaces against harsh conditions such as corrosion, wear, and high temperature. In the current study, chromite mineral was beneficiated and reduced to two different sizes to be used as feedstock material for thermal spray coating. Powders were upgraded by gravity and magnetic separation, respectively, and thermally sprayed onto mild steel samples by using atmospheric plasma spray (APS) equipment. Morphology, structure, phases, elemental distribution of chromite powder, and coatings were studied using field emission scanning electron microscopy, X-ray diffraction, X-ray fluorescence spectroscopy, and energy-dispersive X-ray spectroscopy. Tribological properties of APS chromite coatings were investigated by using a ball-on-disk tribometer, and corrosion resistance properties were evaluated by carrying out potentiodynamic polarization testing in 3.5% NaCl solution. It is observed that the coating has better wear and corrosion resistance and is worn by abrasive wear that includes scratching and particles pull out. Coating efficiency, surface morphology, and microhardness of the coating developed by fine powder were better than those of coarse powder coating.