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Effect of Heat Treatment on the Microstructure and Corrosion Behavior of Arc-Sprayed FeCrAl/Al Coating

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Abstract

Arc spraying provides a simple and efficient process for fabricating Fe-based alloy coatings to protect metal surfaces against corrosion. In this study, FeCrAl/Al coatings were deposited on low carbon steel substrates by arc spraying and subsequently heat-treated within a temperature range of 300-700 °C for 1 h. The microstructure of the coatings was characterized and tested in 3.5 wt.% NaCl solution. The as-sprayed coating had a dense-layered structure comprised of alternating FeCrAl and Al splats. The porosity of the coatings was lowest at 300 °C. Further increase in temperature to 700 °C increased the porosity and cracks along the intersplat boundaries. The coating heat-treated at 400 °C had the highest adhesion strength of 46.11 ± 4.81 MPa. Elemental diffusion of Fe and Al elements formed Fe2Al5 intermetallic compounds at 500 °C. The FeAl phases influenced the microstructure and coating properties. The coating heat-treated at 600 °C had the highest microhardness of 523.06 ± 21.61 HV0.1. The highest corrosion resistance was obtained for the coating at 300 °C, attributed to the lower porosity and protective oxide films.

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Acknowledgments

This work was supported by the Jiangsu Provincial Key Research and Development Plan (BE2020311).

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Authors and Affiliations

  1. College of Engineering, Nanjing Agricultural University, Nanjing, 210031, China

    Joseph Ndiithi Ndumia, Bertrand Vigninou Gbenontin, Min Kang, Xin Liu & Samuel Mbugua Nyambura

  2. Nanjing Research Institute for Agricultural Mechanization, Ministry of Agriculture and Rural Affairs, Nanjing, 210000, China

    Jiping Zhu

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  1. Joseph Ndiithi Ndumia
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Correspondence to Min Kang.

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Ndumia, J.N., Zhu, J., Gbenontin, B.V. et al. Effect of Heat Treatment on the Microstructure and Corrosion Behavior of Arc-Sprayed FeCrAl/Al Coating. J. of Materi Eng and Perform 32, 1489–1497 (2023). https://doi.org/10.1007/s11665-022-07241-1

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  • DOI: https://doi.org/10.1007/s11665-022-07241-1

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