Corrosion resistance of Fe-based amorphous metallic matrix coating fabricated by HVOF thermal spraying

The Fe-based amorphous metallic matrix coating (Fe-AMMC) was fabricated with the powder mixtures of Fe-based metallic glass synthesized with industrial raw materials, NiCr alloy and WC particle by high velocity oxy-fuel (HVOF) spraying. The corrosion resistance of Fe-AMMC was investigated by potentiodynamic polarization tests in 1 mol/L HCl, NaCl, H2SO4 and NaOH solutions, respectively. The surface morphologies corroded were observed by SEM. The results indicate that Fe-AMMC exhibits excellent corrosion resistance, higher corrosion resistance than 304L stainless steel in the chloride solutions. The low corrosion current density and passive current density of Fe-AMMC with a wide spontaneous passivation region are about 132.0 μA/cm2 and 9.0 mA/cm2 in HCl solution, and about 2.5 μA/cm2 and 2.3 mA/cm2 in NaCl solution. The excellent corrosion resistance demonstrates that Fe-based amorphous metallic matrix powder is a viable engineering material in practical anti-corrosion and anti-wear coating applications.