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Double glow plasma surface metallurgy (DGPSM) technology was applied to obtain a Fe-Al-Cr coating on the surface of Q235 carbon steel. The influence of the sample temperature, gas pressure, the distance between the substrate, and the source electrode on the quality of the obtained Fe-Al-Cr coatings was systematically investigated. The results showed that the parameters for DGPSM have a significant effect on the uniformity, particle size, compactness, and thickness of the coating. Under the optimized parameters (sample temperature: 800 °C, gas pressure: 35 Pa, and electrode distance: 15 mm), the obtained Fe-Al-Cr coating contains Fe2AlCr, Fe3Al(Cr), FeAl(Cr), Fe(Cr) solid solution, Cr23C6, and α-Fe(Al), exhibiting excellent corrosion resistance in a 0.5 mol/L H2SO4 solution, which is even better than that of the 304 stainless steel.

Double Glow Plasma Surface Metallurgy Technology Fabricated Fe-Al-Cr Coatings with Excellent Corrosion Resistance