Linz-Donawitz slag (LDS) is a major solid waste generated in huge quantities during steel making. Although a number of ways for its utilization have been suggested in the past, its potential as a possible erosion resistant coating material has not yet been explored. This work is an attempt to develop functional coatings of this LDS on metal substrates by plasma spraying. The coating deposition is carried out using an 80 kW atmospheric plasma spray system working in non-transferred arc mode at different torch input powers (10–24 kW). Coatings are characterized in terms of their thickness and adhesion strength. Coating deposition efficiency is calculated to assess the coatability and XRD is done to ascertain the phases present in the coating. It is found that the operating power levels of the plasma torch affect the adhesion strength, deposition efficiency and mean thickness of the coatings. Solid particle erosion trials, as per ASTM G76 test standards, are conducted on the coating samples following a well planned experimental schedule based on Taguchi design of experiments. This work reveals that LDS is eminently coatable with deposition efficiency as high as 33% and can be gainfully used as a cost-effective wear resistant coating material.

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