Abstract
Intermetallic compounds formed during heat treatment of alloy coatings affect the coating structure and properties. In order to determine the phase changes and coating performance, FeCrAl (Fe Bal., Cr 26 wt.%, Al 6 wt.%) and Al (99.9 wt.%) coating was sprayed onto low carbon steel substrates and subsequently heat-treated at different temperatures. The effects of heat treatment on the microstructure, phase composition, tensile bonding strength, microhardness, and wear properties of the coatings were analyzed. The as-sprayed coating had a dense, layered structure with an average porosity of 3.6%. The microhardness of the as-sprayed coating was comprised of hard FeCrAl splats and ductile Al splats with an average microhardness value of 494 HV0.1. The coating at 300 °C had the highest tensile strength of 37.5 MPa. At 500 °C, FeAl intermetallic compounds formed at the phase boundaries due to the diffusion of elements. The coating microhardness and wear resistance were affected by the uniform coating structure and the precipitation of FeAl intermetallic compounds. Compared with the annealed coatings, the as-sprayed coating had the lowest wear rate.
Highlights
The arc spraying process is commonly used for protecting steel materials and remanufacturing worn parts so as to increase their service life
FeCrAl applied by arc spraying has been used to improve the corrosion resistance of H13 steel hot dipped in aluminum [9]
FeCrAl/Al coatings were prepared in this study, and the effects of heat treatment on the microstructure, phase formation, tensile bonding strength, and wear behavior were investigated
Summary
The arc spraying process is commonly used for protecting steel materials and remanufacturing worn parts so as to increase their service life. Fe-based alloy materials such as FeCrAl possess suitable wear and corrosion properties in medium-to-high temperatures and substitute NiAl bond coatings due to their good adhesion properties [4,5]. Al acts as a barrier coating by forming passive protective films that enhance the corrosion and high-temperature resistance [7]. FeCrAl applied by arc spraying has been used to improve the corrosion resistance of H13 steel hot dipped in aluminum [9]. Arc spraying two different pre-alloyed wires can develop pseudo-alloy coatings with better properties than the individual materials [10]. Several studies have been carried out to deposit pseudo-alloy coatings using arc spraying processes such as 321 stainless steel/Al [10], Zn/Al [13], and Ti/Al [10,14]
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
