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Hot-Gas Corrosion-Erosion Resistance of Thermally Post-Treated Fe-Al-Based Arc-Sprayed Coating


 Solid-particle erosion of metals and alloys at elevated temperatures is one of the main reasons of the damage of components used in the energy production and utilization industries. Application of protective coating systems can be an attractive and economically reasonable solution for preventing the failure and increasing the durability of the components working in severe conditions of high-temperature corrosion and erosion. However, thermal spraying of intermetallic materials that have excellent high-temperature corrosion resistance is limited because of their low ductility. Present work reports the results of the investigation of abrasion wear resistance at elevated temperatures of combined coatings, which include the intermetallic layer. Such iron aluminide layers have been formed as a result of diffusion during the heat post-treatment of arc-prayed metallic coatings combining Fe- and Al-based layers. Post-treatment of arc-sprayed coatings was carried out by means of infrared radiation and induction heating. It was shown that the abrasion resistance of the developed coating tested at elevated temperatures (T > 500 °C) is considerably higher than that of low-alloyed steel and some nickel-based alloys and depends on the test load condition. The high performance of intermetallic-based graded coatings at elevated temperatures makes them interesting for applications as a low-cost erosion-corrosion-resistant material.