Abstract
High velocity arc spraying was used to prepare FeCrAl/Al composite coating on Q235 steel substrate by simultaneously spraying FeCrAl wire as the anode and Al wire as the cathode. The composite coating was sprayed with varying voltage and current to obtain optimum coating characteristics. FeCrAl coating was also prepared for comparison purposes. The surface microstructure of the coatings was characterized by scanning electron microscope (SEM) and X-ray diffraction (XRD). The average microhardness of the coatings and the substrate was analyzed and compared. Corrosion resistance was investigated by means of electrochemical tests. The image results showed that a lamellar structure consisted of interwoven layers of FeCrAl and Al. Al and FeCr constituted the main phases with traces of oxides and AlFe intermetallic compounds. The average porosity was reduced and microhardness of the coatings was improved with increasing voltage and current. The FeCrAl/Al coating formed alternating layers of hard and ductile phases; the corrosion resistance of the coatings in the sodium chloride (NaCl) solution depended on the increase in Al content and spray parameters. The corrosion resistance tests indicated that FeCrAl/Al coating had a better corrosion resistance than the FeCrAl coating. FeCrAl/Al can be used to coat steel substrates and increase their corrosion resistance.
Highlights
Steel components are used extensively in the chemical, bridge construction, agricultural equipment, and other industries
Q235 steel is a common material for the main components of mechanical equipment
Sprayed coating methods can be used to increase service life of these machine parts and structures made of Q235 steel
Summary
Steel components are used extensively in the chemical, bridge construction, agricultural equipment, and other industries. Q235 steel is a widely used material in these industries for its relatively good mechanical properties. Q235 steel is a common material for the main components of mechanical equipment. Besides having relatively lower cost than stainless steels and superalloys, this material has good machinability and welding performance [1]. Sprayed coating methods can be used to increase service life of these machine parts and structures made of Q235 steel. It is of great value and significance to study the structure and properties of coatings on Q235 steel
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