Corrosion Behavior of Fe-Al Coatings Fabricated by Pack Aluminizing Method

In this study, the two kinds of Fe–Al coatings were fabricated by pack aluminizing on low-carbon steel at different temperatures. The corrosion behavior of the Fe–Al coatings in artificial seawater was investigated by the electrochemical and weight loss techniques. Results show that the thickness of coating layer increases with increasing aluminizing temperature. The coatings exhibit high micro-hardness and good metallurgical bonding with the substrate. In comparison with the steel substrate, the corrosion current density I corr of the Fe–Al coatings is always lower than that of substrate, about 1/38 or 1/33 after 2 h immersion, and 1/3 or 1/6 for 720 h immersion. As can be seen from the weight loss curve, the Fe–Al coatings show less loss than that of the substrate within 30-day immersion. The corrosion products formed on the surface of the coatings include oxides of Al, Mg, Fe and Ca, and pitting defect has also been found. The Fe–Al coating with higher content of Fe2Al5 has better corrosion resistance.