In the present study cenopshere was reinforced with FeCrNiC (Metco 42C) as matrix material and prepared four different feedstock powders such as FeCrNiC+0%Cenosphere, FeCrNiC+5%Cenosphere, FeCrNiC+10%Cenosphere and FeCrNiC+15%Cenosphere were coated by plasma spray technique on T22 substrate. Evaluation of the substrate and coatings potential under salt spray test was performed. Dense fog of 5% NaCl salt water was used to create a corrosive atmosphere within the chamber. The salt water's pH was kept constant at 6.5-7. The materials that underwent corrosion were examined using X-ray diffraction (XRD), and scanning electron microscopy (SEM). The FeCrNiC+15%Cenosphere and FeCrNiC+10%Cenosphere coatings exhibited reduced weight loss during a 168-hour corrosion test compared to the FeCrNiC+5%Cenosphere, FeCrNiC coatings, and substrate. The excellent chemical stability and corrosion resistance of Cr23C6, SiO2, NiO, and Cr2O particles contribute to gradually avoid the formation of red rust on Fe-based coated samples with exposure approaches to 52 and 130 hours.
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