Spray powder with a superferritic iron-based compound as well as a substrate, in particular a brake disk with a thermal spray layer

The spray powder of clam 1, wherein said amounts are:

• C at a maximum up to 0.5%;
• Mn at a maximum up to 0.5%;
• Ni at a maximum up to 0.3%;
• Nb at a maximum up to 0.8%;
• P at a maximum up to 0.05%;
• S at a maximum up to 0.05%;
• Si at a maximum up to 0.15%;
• Cr in the range from 25% to 35% by weight;
• Mo in the range 3.5% to 4.5% by weight;
• and
• a remainder of Fe;
• a total of a maximum of 0.3% by weight of impurities;
• and
• said ceramic component comprising Al2O3 and ZrO2 is from 10% up to a maximum of 40% by weight.

A substrate with a thermal spray layer that comprises a superferritic iron-based compound and a ceramic component comprising Al2O3 and ZrO2;

• said superferritic iron-based compound having C, Mn, Cr, Mo, Ni, Nb, P, S, Si, Fe, Al, O and Zr, wherein amounts are:
• C at a maximum up to 0.7% by weight;
• Mn at a maximum up to 0.7% by weight;
• Ni at a maximum up to 0.5% by weight;
• Nb at a maximum up to 1.2% by weight;
• P at a maximum up to 0.1% by weight;
• S at a maximum up to 0.1% by weight;
• Si at a maximum up to 0.2% by weight;
• Cr in the range from 20% to 40% by weight;
• Mo in the range 2.0% to 6% by weight;
• a remainder of Fe;
• and
• a total of a maximum of 0.4% by weight of impurities;
• and
• said ceramic component comprising Al2O3 and ZrO2 being in an amount of up to a maximum of 50% by weight of said thermal spray layer,
• wherein the ceramic component comprising Al2O3 and ZrO2 contains between 60% and 90% by weight Al2O3 and between 10% and 40% by weight ZrO2.

A thermal spray coating layer arranged on a substrate and comprising a superferritic iron-based metal matrix and inclusions of ceramic component comprising Al2 O3 and ZrO2;

• said superferritic iron-based metal matrix that includes only elements from the following;
• C, Mn, Cr, Mo, Ni, Nb, P, S, Si, Fe, Al, O and Zr,
• wherein amounts of the elements are:
• C at a maximum up to 0.7% by weight;
• Mn at a maximum up to 0.7% by weight;
• Ni at a maximum up to 0.5% by weight;
• Nb at a maximum up to 1.2% by weight;
• P at a maximum up to 0.1% by weight;
• S at a maximum up to 0.1% by weight;
• Si at a maximum up to 0.2% by weight;
• Cr in the range from 20% to 40% by weight;
• Mo in the range 2.0% to 6% by weight;
• a remainder of Fe;
• and
• a total of a maximum of 0.4% by weight of impurities that include elements Al, O and Zr;
• and
• said inclusions of ceramic component comprising Al2O3 and ZrO2 being in an amount of up to a maximum of 50% by weight of said thermal spray coating layer,
• wherein the ceramic component comprising Al2O3 and ZrO2 contains between 60% and 90% by weight Al2O3 and between 10% and 40% by weight ZrO2.