Iron-based coatings arc-sprayed with cored wires for applications at elevated temperatures

► Economically alloyed iron-based Fe-Cr-B-Al core wires were developed for arc spraying. ► Oxidation kinetics, oxide morphology, residual stresses were investigated at 500-700 °C. ► Inner coating oxidation starting from 350 °C improves hot-gas erosion resistance. ► Microheterogeneity coefficient Khm of coating describes chemical uniformity. ► Khm influences coating properties and performance at elevated temperatures.