Corrosion and Wear Behaviors of Fe-Based Composite Coating with Dual Amorphous Phases

doi:10.11900/0412.1961.2023.00449

Acta Metall Sin

2025, Vol. 61

Issue (8): 1267-1275 DOI: 10.11900/0412.1961.2023.00449

Research paper

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Corrosion and Wear Behaviors of Fe-Based Composite Coating with Dual Amorphous Phases

ZANG Bolin¹, YANG Yange²(

), CAO Jingyi¹, XU Fengfeng³, YAO Haihua³(

), ZHOU Zheng³

^1.Unit 92228, People's Liberation Army, Beijing 100072, China
^2.Shi -changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
^3.Faculty of Materials and Manufacturing, Beijing University of Technology, Beijing 100124, China

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ZANG Bolin, YANG Yange, CAO Jingyi, XU Fengfeng, YAO Haihua, ZHOU Zheng. Corrosion and Wear Behaviors of Fe-Based Composite Coating with Dual Amorphous Phases. Acta Metall Sin, 2025, 61(8): 1267-1275.

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Abstract

Fe-based amorphous composite coatings have attracted great attention because their specific properties can be enhanced by introducing other metallic or ceramic particles. This work introduces a novel approach, distinct from traditional methods, by designing a composite coating with dual amorphous phases. The composite coating (named FH) was fabricated using high-velocity oxygen-fuel spraying of a blended amorphous powder. This powder comprised well-established Fe₄₈Cr₁₅Mo₁₄C₁₅B₆Y₂ (named FM) and Fe₅₉Cr₁₂Nb₅B₂₀Si₄ (named FN) amorphous powders. This study focuses on investigating the corrosion and wear behaviors of the FH coating in comparison with those of monolithic amorphous coatings. The findings reveal that the FH coating possesses a high amorphous content and a compact structure. It features a uniform distribution of two types of amorphous splats, with no evident element diffusion. In 3.5%NaCl solution, the FH coating exhibits passivation behavior, similar to the two monolithic amorphous coatings, and yields a lower corrosion current and higher polarization resistance, indicating enhanced its corrosion resistance. This improved corrosion resistance of the FH coating is attributed to a harmonious balance between beneficial alloy elements and its compact structure, addressing the limitations of monolithic amorphous coatings. Furthermore, the FH coating displays a high friction coefficient under dry friction conditions and maintains a low wear rate, comparable to those of the FN coating. The wear mechanisms of the three amorphous coatings under dry friction primarily involve fatigue wear, supplemented by minor abrasive and oxidative wear. Compared to the monolithic amorphous coating, the FH coating shows enhanced interfacial bonding of splats and a balanced combination of strengthening and toughening, which effectively inhibit crack propagation caused by fatigue wear, thereby endowing the coating with superior wear resistance. Therefore, the composite coating with dual amorphous phases achieves a balance in cost efficiency, corrosion resistance, and wear resistance.

Key words: Fe-based amorphous coating composite coating dual amorphous phase corrosion friction and wear

Received: 13 November 2023

ZTFLH:

TG174

Fund: National Natural Science Foundation of China(52371043);National Natural Science Foundation of China(51771005);National Natural Science Foundation of China(52171060)

Corresponding Authors: YANG Yange, professor, Tel: (024)23881473, E-mail: ygyang@imr.ac.cn;
YAO Haihua, Tel: (010)67392168, E-mail: yaohaihua@bjut.edu.cn

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	ZANG Bolin
	YANG Yange
	CAO Jingyi
	XU Fengfeng
	YAO Haihua
	ZHOU Zheng

URL:

https://www.ams.org.cn/EN/10.11900/0412.1961.2023.00449 OR https://www.ams.org.cn/EN/Y2025/V61/I8/1267

Fig.1 XRD spectra of the Fe-based amorphous coatings (FN—Fe₅₉Cr₁₂Nb₅B₂₀Si₄, FM—Fe₄₈Cr₁₅Mo₁₄-C₁₅B₆Y₂, FH—50%FN + 50%FM (mass fraction))

Fig.2 Typical cross-sectional backscattered electron (BSE) images of the FN coating (a), FM coating (b), FH coating (c), and local-area magnification of FH coating (d) with the corresponding EDS results (e, f)

Fig.3 Bright-field TEM images and selected area electron diffraction (SAED) patterns (insets) of FN (a), FM (b), and FH (c) coatings

Fig.4 Potentiodynamic polarization curves of the Fe-based amorphous coatings in 3.5%NaCl solution (SCE—saturated calomel electrode)

Table 1 Corrosion parameters obtained from potentiodynamic polarization curves

Fig.5 Nyquist (a) and Bode (b) plots of the Fe-based amorphous coatings in 3.5%NaCl solution (Inset in Fig.5a is the equivalent circuit of coatings for EIS fitting. Z'—real part of the impedance, Z''—imaginary part of the impedance, |Z|—modulus of impedance, R_s—solution resistance, R_t—charge transfer resistance,CPE-dl—constant phase angle element related to electric double layer capacity, CPE-f—constant phase angle element related to passive film capacity, R_f—passive film resistance)

Table 2 Equivalent electrical circuit parameters for impedance spectra of the Fe-based amorphous coatings

Fig.6 Friction coefficient curves of the Fe-based amorphous coatings measured as a function of time

Fig.7 3D morphologies (unit: μm) (a, c, e) and measured results (b, d, f) of the wear tracks of Fe-based amorphous coatings (a, b) FN (c, d) FM (e, f) FH

Fig.8 Microhardnesses and wear rates of the Fe-based amorphous coatings

Fig.9 Low (a, c, e) and high (b, d, f) magnified worn surface morphologies of the Fe-based amorphous coatings
(a, b) FN (c, d) FM (e, f) FH

Table 3 EDS results of the marked regions in Fig.9

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