Wear and Corrosion Behavior of Wire-arc Sprayed Fe-based Coatings

Cored wires Fe-Cr-P-B-C system was designed, and coatings were prepared by twin wire arc spraying on Q235 substrate.The influence law on microstructure, wear resistance and electrochemical corrosion resistance of coatings with phosphorus were investigated by X-ray diffraction (XRD), scanning electron microscope (SEM), abrasive wear testing machine, and electrochemical workstation. Results showed that the as-deposited coatings consisted of numerous flattened lamellae parallel to the substrate.The porosities of coatings were about 3%-4%.The coatings were amorphous/nanocrystalline composite coatings.However, the partial substitution P for B in the alloy system resulted in the reduction of amorphous content.The microhardness and wear resistance decreased slightly with the increase of x(P), but not notable.The abrasive wear resistance of coatings was 5-8 times higher than that of the Q235 substrate.The free corrosion potential increased after adding the phosphorus element into the coatings, which was beneficial to corrosion resistance of coatings.In this study, the coating with 2% phosphorus addition had comparatively better wear and corrosion resistance.