Characterization of FeCr and FeCoCr alloy coatings of carbon steels for marine environment applications

Abstract

This paper presents the adhesive strength results of FeCr and FeCoCr deposits produced by electric arc thermal spray process on carbon steel plates. Five chemical compositions were tested to give a large panel of possibility. Coatings were characterized by several methods to result in a performance screening. The main assessment of microstructural morphology was made by scanning electron microscopy (SEM). The mechanical strength of coatings was evaluated by standard pull-off test. The corrosion resistance was analyzed in salt-spray test. The morphology of coatings exhibits characteristics of lamellar microstructures with incompletely melted particles together with a distribution of similarly oriented oxides. The adhesive strength of FeCoCr alloy coatings was higher amongst all studied conditions. All sealed conditions presented low corrosion in salt-spray exposure. Additionally, a new FeCoCr alloy was studied to reduce pores and microcracks that are frequently found in traditional FeCr and FeCrNi alloys. Based on the performed characterizations, the findings suggested that the FeCoCr deposition, with an epoxy sealing, is suitable to be used as an efficient coating of carbon steel in aggressive marine environments.