Excellent corrosion resistant amorphous coating prepared by gas atomization followed by AC-HVAF spray technology

A novel Fe_49.9Mo_32.9Cr_9.32Co_4.55Si_2.28Al_1.55 amorphous coating was synthesized successfully on 45 steel by gas atomization followed by activated combustion high-velocity air fuel (AC-HVAF) spray technology. During the fabrication process, Fe-base alloy was firstly atomized into amorphous powders by high-speed gas flow, and then the amorphous powders are used to prepare amorphous coating by AC-HVAF spray technology. The research focused on the microstructure and corrosion behavior in the prepared coatings. Results show that an ultra-high volume fraction of amorphous phase over 90% was obtained in the prepared coatings, which significantly improves the corrosion resistance of the coatings under extreme service conditions.