Influence of Heat Treatment on the Microstructure and Wear Properties of Arc-Sprayed FeCrAl/Al Coating

Abstract

Intermetallic compounds formed during heat treatment of alloy coatings affect the coating structure and properties. In order to determine the phase changes and coating performance, FeCrAl (Fe Bal., Cr 26 wt.%, Al 6 wt.%) and Al (99.9 wt.%) coating was sprayed onto low carbon steel substrates and subsequently heat-treated at different temperatures. The effects of heat treatment on the microstructure, phase composition, tensile bonding strength, microhardness, and wear properties of the coatings were analyzed. The as-sprayed coating had a dense, layered structure with an average porosity of 3.6%. The microhardness of the as-sprayed coating was comprised of hard FeCrAl splats and ductile Al splats with an average microhardness value of 494 HV0.1. The coating at 300 °C had the highest tensile strength of 37.5 MPa. At 500 °C, FeAl intermetallic compounds formed at the phase boundaries due to the diffusion of elements. The coating microhardness and wear resistance were affected by the uniform coating structure and the precipitation of FeAl intermetallic compounds. Compared with the annealed coatings, the as-sprayed coating had the lowest wear rate.