Development of a FeCrMnBC-based economical wear and corrosion resistant coating

Abstract Main advantages of Fe-based coatings are their favourable lower costs as well as their good environmental behaviour compared to other established protective coatings. In this study, a highly economical coating system based on a FeCrMnBC alloy was developed, consisting only of economically favourable elements. The coating was produced using a spray powder with a size distribution of −90 + 45 μm by a three-cathode plasma generator TriplexPro™-210 and evaluated in terms of the microstructure, hardness, wear and corrosion resistance. It was found that the coating exhibited a dense lamellar microstructure and a microhardness value of more than HV0.1 = 600. The coating was significantly more wear resistant compared with a plasma sprayed stainless steel coating of 316 L. Salt spray test confirmed that the corrosion behavior of the FeCrMnBC coating was comparable to that of a plasma sprayed 316 L coating. Due to the higher wear resistance, comparable corrosion behavior and lower material costs this new coating system can be used as more economical alternative or replacement to conventional stainless steel coatings to protect carbon steel as well as cast iron parts against wear and corrosion.