Abstract
Among different thermal spraying methods, arc-spraying has been widely used due to its low operating costs and high deposition efficiency. The rapid progress of cored wire technology in arc-spraying has increased possibilities for the preparation of new Fe-based coating materials with enhanced properties by adding reinforcement particles and alloying elements to suit the different applications. Fe-based coatings have been extensively used because of their high strength, toughness, lower production costs, and availability of raw materials. This makes them suitable replacements for Ni-based coatings in ambient and high-temperature applications. This review discusses the research status and developments of the arc-sprayed Fe-based coatings. The study specifically reviews the wear behavior, corrosion analysis, and high-temperature resistant properties of arc-sprayed Fe-based coatings, aiming to develop an understanding of the protection mechanisms for Fe-based coatings. The performance of the Fe-based coatings depends on the integrity of the coating structure. Optimizing arc-spraying parameters minimizes defects (pores, grain boundaries, unmelted particles, oxides, and microcracks) that deteriorate the coating properties. High amorphous phase content, ceramic reinforcement particles and alloying elements enhance the corrosion, tribological, and high-temperature resistant properties of Fe-based coatings. In high-temperature applications, Fe-based coatings form oxide scales that protect the coating from further oxidation; thus, it is important to select the optimum composition for the alloying elements.
Highlights
In recent years, thermal spraying-as a surface modification process-produces films and coatings that improve the properties of metal surfaces
The high hardness, fracture toughness, and good adhesion strength properties increase the wear-resistance of Fe-based alloy coatings in their potential applications
This study provides a major contribution in the advancement of knowledge on the effects of elemental composition on High-Temperature Erosion (HTE) behavior
Summary
Thermal spraying-as a surface modification process-produces films and coatings that improve the properties of metal surfaces. New processes and coating materials developed with suitable properties improve the functionality and application of arc-sprayed coatings in different environments. To enhance the high-temperature and corrosion properties, Cr is widely used in Ni-based and Fe-based alloys because it forms the protective Cr2 O3 oxide layer [11]. Li et al [12] prepared arc-sprayed FeCrSiB and observed that adding Si and B elements reduced the oxide inclusions and increased hardness in the coating compared with NiCrTi and FeCr. Table 1 shows a comparison of properties for arc-sprayed Fe-based and Ni-based coatings. Fe-based amorphous/nanocrystalline coatings with high metallic glass content, dense structure, and low porosity have been fabricated using arc-spraying [16,17]. The addition of glass-forming elements (such as B, P, C, Mo, and Si) can generate a certain amount of amorphous content, which improves the hardness and toughness of the coating [19,20,21]
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