Abstract
Alloyed Fe3Si intermetallic compound coatings were prepared through non-electrolysis high-temperature infiltration in molten salt on the surface of AISI420 and AISI304 stainless steel containing Cr and Cr, Ni elements, compared with Fe3Si coating on A3 carbon steel surface. The microstructure of infiltration coatings was examined by means of X-ray diffraction (XRD), scanning electron microscopy (SEM), and glow discharge optical emission spectroscopy. The electrochemical corrosion properties and behavior of Fe3Si coatings in H2SO4 solution were evaluated via electrochemical techniques and static immersion tests. The results revealed that the permeation coatings prepared on the stainless steel surface are composed of a Cr- and Cr-, Ni-alloyed Fe3Si intermetallic-compound layer and a diffusion layer. Owing to the presence of alloying elements Cr and Ni from the substrate, the permeation coatings were relatively thick, dense, and contained only a few defects. The Cr-, Ni-alloyed Fe3Si coating prepared on AISI304 surface was the most compact, contained fewer defects, and was thicker than the coating prepared on AISI420. The Fe3Si infiltration coatings exhibited significant passivation characteristics in 10 vol% H2SO4 aqueous solution. Alloyed Fe3Si coatings of AISI420 and AISI304 exhibit better corrosion resistance in 10 vol% and 20 vol% H2SO4 than the Fe3Si coating of carbon steel. Therefore, these coatings can protect both types of stainless steel from surface corrosion. The best corrosion resistance was realized for the alloyed Fe3Si coating on AISI304 surface. The corrosion resistance and protection performance of Fe3Si intermetallic-compound coatings in H2SO4 solution are directly correlated with the thickness, compactness, defect characteristics, and passivation properties of the infiltration coatings. However, alloying elements from the alloy steel substrates had a significant effect on these four factors, during the infiltration process in the molten salt.
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