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

1. A spray powder for thermal spray coating comprising a superferritic iron-based compound and a ceramic component comprising Al 2 O 3 and ZrO 2;

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 Al 2 O 3 and ZrO 2 being in an amount of up to a maximum of 50% by weight of said spray powder,

wherein the ceramic component comprising Al 2 O 3 and ZrO 2 contains between 60% and 90% by weight Al 2 O 3 and between 10% and 40% by weight ZrO 2 .

2. 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 Al 2 O 3 and ZrO 2 is from 10% up to a maximum of 40% by weight.

3. The spray powder of claim 1 , wherein said amounts are:

C at a maximum up to 0.017% by weight;

Cr in the range from 27.5% to 29.5% by weight;

Mo in the range 3.8% to 4.2% by weight; and

a remainder of Fe; and

the ceramic component comprising Al 2 O 3 and Zr 0 2 is in range 34% to 36%.

4. The spray powder of claim 1 , wherein the ceramic component comprising Al 2 O 3 and ZrO 2 contains between 75% and 85%, by weight Al 2 O 3 and between 15% and 25%, by weight ZrO 2 .

5. A substrate with a thermal spray layer that comprises a superferritic iron-based compound and a ceramic component comprising Al 2 O 3 and ZrO 2 ;

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 Al 2 O 3 and ZrO 2 being in an amount of up to a maximum of 50% by weight of said thermal spray layer,

wherein the ceramic component comprising Al 2 O 3 and ZrO 2 contains between 60% and 90% by weight Al 2 O 3 and between 10% and 40% by weight ZrO 2 .

6. The substrate of claim 5 , 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 Al 2 O 3 and ZrO 2 is from 10% up to a maximum of 40% by weight.

7. The substrate of claim 5 , wherein said amounts are:

C at a maximum up to 0.017% by weight;

Cr in the range from 27.5% to 29.5% by weight;

Mo in the range 3.8% to 4.2% by weight; and

a remainder of Fe; and

the ceramic component comprising Al 2 O 3 and ZrO 2 is in the range 34% to 36%.

8. The substrate of claim 7 , wherein the ceramic component comprising Al 2 O 3 and ZrO 2 contains between 75% and 85%, by weight Al 2 O 3 and between 15% and 25%, by weight ZrO 2 .

9. The substrate of claim 5 , wherein the thermal spray layer is a compound layer of a matrix containing metal and having inclusions including the ceramic component comprising Al 2 O 3 and ZrO 2 .

10. The substrate of claim 5 , wherein a porosity of the thermal spray layer is less than 5%.

11. The substrate of claim 5 , wherein a microhardness of the thermal spray layer is between 300 HV.03 and 1000 HV.03.

12. The substrate of claim 5 , wherein a thickness of the thermal spray layer is between 50 μm and 500 μm.

13. The substrate of claim 5 , wherein the substrate includes aluminum or an aluminum alloy.

14. The substrate of claim 5 , wherein the substrate is a brake disk.

15. The substrate of claim 14 , wherein the brake disk is a vehicle or motor vehicle brake disk.

16. The substrate of claim 5 , further comprising an adhesive layer arranged between the thermal spray layer and the substrate, wherein the adhesive layer comprises at least one of:

Ni and Al; and/or

Ni and Cr.

17. The substrate of claim 5 , wherein the thermal spray layer is one of:

a thermal spray layer applied by a powder flame spraying process;

a thermal spray layer applied by a high-velocity powder flame spraying process; or

a thermal spray layer applied by a plasma spraying process.

18. A thermal spray coating layer arranged on a substrate and comprising a superferritic iron-based metal matrix and inclusions of ceramic component comprising Al 2 O 3 and ZrO 2 ;

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 Al 2 O 3 and ZrO 2 being in an amount of up to a maximum of 50% by weight of said thermal spray coating layer,

wherein the ceramic component comprising Al 2 O 3 and ZrO 2 contains between 60% and 90% by weight Al 2 O 3 and between 10% and 40% by weight ZrO 2 .