The effect of high-velocity oxy-fuel spraying parameters on microstructure, corrosion and wear resistance of Fe-based metallic glass coatings

• Revealing the correlation among parameters and microstructure of Fe-based coatings
• The amorphous phase content of the Fe-based coatings varies with varying spray power.
• The wear resistance of Fe-based coatings increases with increasing spraying power.
• Fe-based coatings exhibit better corrosion resistance than 316L stainless steel.

Fe-based amorphous coatings were deposited on 1Cr18Ni9Ti stainless steel substrates by high velocity oxy-fuel spraying (HVOF) at different spraying parameters. It has been found that the amorphous phase content of the as-sprayed coatings rises initially and declines later with the increase of spraying power, which is due to the competition between melting and oxidation degree of the feedstock powder and the thermal radiation effect of the flame. Besides, the microhardness and wear resistance of the as-sprayed coatings increase with increasing spraying power, which is attributed to the enhancement of splat-to-splat binding force at elevated spraying power. Moreover, the three kinds of Fe-based amorphous coatings obtained under different spraying parameters all exhibit better corrosion resistance than 316L stainless steel. Particularly, the Fe-based amorphous coating deposited at an intermediate spraying power exhibits dense structure as well as the highest amorphous phase content, the best corrosion resistance, and very good wear resistance, showing promising potential as a candidate for surface protective and anticorrosion coatings for the stainless steel.