Abstract
Fe–Al intermetallic coating was prepared on steel substrate by plasma spraying. The corrosion behavior of the Fe–Al coating in molten zinc at 640 °C was investigated in detail. The results showed that the plasma spraying Fe–Al coating was composed of FeAl and (Fe 2Al 5 + FeAl 2) eutectic structure. In the molten zinc corrosion process, (Fe 2Al 5 + FeAl 2) eutectic structure was corroded preferentially. FeAl 2 disappeared in the initial stage of corrosion. The phase transition process of Fe 2Al 5 induced by molten zinc corrosion was Fe 2Al 5 → Fe 2Al 5Zn x ( η) → η + L (liquid phase) → η + δ(FeZn 7) + L → L. And the phase transition process of FeAl induced by molten zinc corrosion was FeAl → FeAlZn x → δ+FeAlZn x → δ + α + Γ(Fe 3Zn 10) → δ + Γ → δ+L → L. The order of corrosion resistance of FeAl 2, FeAl and Fe 2Al 5 against 640 °C molten zinc was FeAl > Fe 2Al 5 > FeAl 2. The results may provide us a useful guide to design Fe–Al intermetallic coating with high corrosion resistance.
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