Microstructure and high-temperature oxidation behavior of wire-arc sprayed Fe-based coatings

Abstract A series of Fe– x Cr cored wires ( x  = 15, 20, 25, 30, 35 and 40% in weight) were used to produce protective coatings for components used in high-temperature environments by wire-arc spraying. The microstructure, morphology and high-temperature oxidation behavior of the Fe– x Cr coatings were investigated. The Fe– x Cr coatings presented a homogeneous structure with thin oxide inclusions and low porosity. Thermogravimetric analysis was used to evaluate the high-temperature oxidation behavior of the coatings at a temperature of 650 °C under cyclic oxidation conditions. The results showed that all the Fe– x Cr coatings exhibited significantly lower weight gain than the uncoated substrate. As Cr content of the coatings increased, the thickness of oxide scales decreased and oxidation resistance improved.