This work aims to study the effect of mechanical milling of Fe, ZnO, and Ni elemental powders and thermal spraying processes on chemical composition, structural properties, and magnetic behavior of the Fe60–xNix(ZnO)40 coatings. As the first step, the FeNi/ZnO composite was synthesized by mechanical alloying process, and afterward, the milled powder was coated by a thermal spraying technique on a steel substrate. Obtained samples were characterized by the methods of X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), atomic force microscopy (AFM), and with help of vibrating sample magnetometer (VSM). After mechanical milling, the crystallite size of the powder decreased from 18 to 10 nm, while the lattice strain increased from 0.31 to 0.59%, and a new solid solution FeNi formed after 20 h of milling due to diffusion of nickel into the iron lattice. After the thermal spraying process, different phases appeared in a surface coating such as ZnFe2O4, NiFe2O4, and FeNi. The magnetic and structural properties of the coated powders are influenced by the change in chemical composition. Thus, the increase of Ni concentration improved the soft magnetic performance of the coating significantly. The highest saturation magnetization was determined in Fe40Ni20(ZnO)40 sprayed powder. However, the smallest coercivity appeared in Fe50Ni10(ZnO)40 sprayed powder.

中文翻译：

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Fe60-xNix(ZnO)40 纳米复合材料的结构和磁性能通过机械研磨生产并通过热喷涂涂覆在钢基材上

本工作旨在研究 Fe、ZnO 和 Ni 元素粉末的机械研磨和热喷涂工艺对 Fe60-xNix(ZnO)40 涂层的化学成分、结构性能和磁性能的影响。首先，通过机械合金化工艺合成 FeNi/ZnO 复合材料，然后通过热喷涂技术将研磨后的粉末涂覆在钢基材上。通过X射线衍射（XRD）、扫描电子显微镜（SEM）、能量色散谱（EDS）、原子力显微镜（AFM）和振动样品磁强计（VSM）等方法对所得样品进行表征。机械研磨后，粉末的晶粒尺寸从 18 nm 减小到 10 nm，而晶格应变从 0.31% 增加到 0.59%，由于镍扩散到铁晶格中，研磨 20 小时后形成了新的固溶体 FeNi。热喷涂工艺后，不同的相出现在表面涂层中，如 ZnFe2O4、NiFe2O4 和 FeNi。涂层粉末的磁性和结构性能受化学成分变化的影响。因此，Ni浓度的增加显着提高了涂层的软磁性能。在 Fe40Ni20(ZnO)40 喷涂粉末中测定了最高饱和磁化强度。但是，Fe50Ni10(ZnO)40喷涂粉末的矫顽力最小。涂层粉末的磁性和结构性能受化学成分变化的影响。因此，Ni浓度的增加显着提高了涂层的软磁性能。在 Fe40Ni20(ZnO)40 喷涂粉末中测定了最高饱和磁化强度。但是，Fe50Ni10(ZnO)40喷涂粉末的矫顽力最小。涂层粉末的磁性和结构性能受化学成分变化的影响。因此，Ni浓度的增加显着提高了涂层的软磁性能。在 Fe40Ni20(ZnO)40 喷涂粉末中测定了最高饱和磁化强度。但是，Fe50Ni10(ZnO)40喷涂粉末的矫顽力最小。