A Review on the Wear, Corrosion and High-Temperature Resistant Properties of Wire Arc-Sprayed Fe-Based Coatings

Abstract

Among different thermal spraying methods, arc-spraying has been widely used due to its low operating costs and high deposition efficiency. The rapid progress of cored wire technology in arc-spraying has increased possibilities for the preparation of new Fe-based coating materials with enhanced properties by adding reinforcement particles and alloying elements to suit the different applications. Fe-based coatings have been extensively used because of their high strength, toughness, lower production costs, and availability of raw materials. This makes them suitable replacements for Ni-based coatings in ambient and high-temperature applications. This review discusses the research status and developments of the arc-sprayed Fe-based coatings. The study specifically reviews the wear behavior, corrosion analysis, and high-temperature resistant properties of arc-sprayed Fe-based coatings, aiming to develop an understanding of the protection mechanisms for Fe-based coatings. The performance of the Fe-based coatings depends on the integrity of the coating structure. Optimizing arc-spraying parameters minimizes defects (pores, grain boundaries, unmelted particles, oxides, and microcracks) that deteriorate the coating properties. High amorphous phase content, ceramic reinforcement particles and alloying elements enhance the corrosion, tribological, and high-temperature resistant properties of Fe-based coatings. In high-temperature applications, Fe-based coatings form oxide scales that protect the coating from further oxidation; thus, it is important to select the optimum composition for the alloying elements.

Surface Characteristics of Vacuum-Plasma-Sprayed Reinforced Stainless Steel Coatings with TiC Particles

“…The use of a newly developed thermal spraying technique has enabled the production of amorphous Fe-based coating films with high hardness and corrosion resistance [29]. These coatings have been found to exhibit wear, corrosion and high-temperature-resistant properties, with the performance depending on the coating structure and the presence of reinforcement particles and alloying elements [30]. However, the wear behavior of these coatings, particularly in power generation plants, has also been investigated, revealing the presence of various phases and inhomogeneities [31].…”

Insight into the Hot Corrosion Behavior of FeMnCrSi/TiC Coatings at 900 °C

“…Fe-Mn-Cr system alloys, renowned for their exceptional mechanical properties and high-temperature oxidation resistance below 600~900 • C, are cost-effective alternatives to Ni-based alloys in certain industrial sectors [14][15][16][17][18]. Extensive research has been conducted on the mechanism of high-temperature oxidative corrosion in Fe-Mn-Cr system alloys.…”

Research Progress and Development Trend of Amorphous and Nanocrystalline Composite Coatings: A Review

“…19 Ndumia introduced the development on the wear, corrosion and high-temperature-resistant properties of wire arc-sprayed Fe-based coatings. 20 General review articles are only introduced for one process or one system, but few total introductions on amorphous coating systems, processes and properties are documented. This paper focused on the current research progress in the preparation of amorphous coatings by high-energy beam surface rapid prototyping at home and abroad and summarizes the research status of the preparation technology, material system and comprehensive properties of amorphous coatings.…”