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High velocity arc spraying was used to prepare FeCrAl/Al composite coating on Q235 steel substrate by simultaneously spraying FeCrAl wire as the anode and Al wire as the cathode. The composite coating was sprayed with varying voltage and current to obtain optimum coating characteristics. FeCrAl coating was also prepared for comparison purposes. The surface microstructure of the coatings was characterized by scanning electron microscope (SEM) and X-ray diffraction (XRD). The average microhardness of the coatings and the substrate was analyzed and compared. Corrosion resistance was investigated by means of electrochemical tests. The image results showed that a lamellar structure consisted of interwoven layers of FeCrAl and Al. Al and FeCr constituted the main phases with traces of oxides and AlFe intermetallic compounds. The average porosity was reduced and microhardness of the coatings was improved with increasing voltage and current. The FeCrAl/Al coating formed alternating layers of hard and ductile phases; the corrosion resistance of the coatings in the sodium chloride (NaCl) solution depended on the increase in Al content and spray parameters. The corrosion resistance tests indicated that FeCrAl/Al coating had a better corrosion resistance than the FeCrAl coating. FeCrAl/Al can be used to coat steel substrates and increase their corrosion resistance.

Microstructural and Corrosion Behavior of High Velocity Arc Sprayed FeCrAl/Al Composite Coating on Q235 Steel Substrate