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Open AccessArticle

Corrosion Behavior of Detonation Gun Sprayed Fe-Al Type Intermetallic Coating

Department of Advanced Materials and Technologies, Faculty of Advanced Technologies and Chemistry, Military University of Technology, 2 Kaliskiego St., Warsaw 00-908, Poland
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Academic Editor: Marco Salerno
Materials 2015, 8(3), 1108-1123; https://doi.org/10.3390/ma8031108
Received: 20 December 2014 / Revised: 6 March 2015 / Accepted: 9 March 2015 / Published: 13 March 2015
(This article belongs to the Special Issue Intermetallic Alloys: Fabrication, Properties and Applications)
The detonation gun sprayed Fe-Al type coatings as an alternative for austenitic valve steel, were investigated using two different methods of testing corrosion resistance. High temperature, 10-hour isothermal oxidation experiments at 550, 750, 950 and 1100 °C show differences in the oxidation behavior of Fe-Al type coatings under air atmosphere. The oxide layer ensures satisfying oxidation resistance, even at 950 and 1100 °C. Hematite, α-Al2O3 and metastable alumina phases were noticed on the coatings top surface, which preserves its initial thickness providing protection to the underlying substrate. In general, only negligible changes of the phase composition of the coatings were noticed with simultaneous strengthening controlled in the micro-hardness measurements, even after 10-hours of heating at 1100 °C. On the other hand, the electrochemical corrosion tests, which were carried out in 200 ppm Cl (NaCl) and pH ~4 (H2SO4) solution to simulate the acid-rain environment, reveal higher values of the breakdown potential for D-gun sprayed Fe-Al type coatings than the ones for the bulk Fe-Al type alloy and Cr21Mn9Ni4 austenitic valve steel. This enables these materials to be used in structural and multifunctional applications in aggressive environments, including acidic ones. View Full-Text
Keywords: FeAl intermetallic coatings; D-gun spraying; corrosion resistance FeAl intermetallic coatings; D-gun spraying; corrosion resistance
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Senderowski, C.; Chodala, M.; Bojar, Z. Corrosion Behavior of Detonation Gun Sprayed Fe-Al Type Intermetallic Coating. Materials 2015, 8, 1108-1123.

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