Production and Corrosion Resistance of Thermally Sprayed Fe-Based Amorphous Coatings from Mechanically Milled Feedstock Powders

Mechanically milled FeCrNbB feedstock powders from commercial precursors were used to produce amorphous coatings through two different industrial thermal-spraying techniques: high-velocity oxygen fuel (HVOF) and flame spraying. Microstructure, thermal behavior, and hardness of the coatings and their corrosion resistances in acidic and alkaline chloride-rich media were comparatively studied. HVOF process was effective to produce ~?200-µm-thick highly amorphous coatings with hardness over than 700 HV_0.3 and low porosity (~?5 pct). Flame-sprayed ~?220-µm-thick coatings were nanocrystalline, composed of α-Fe, Fe₂B, FeNbB, and Fe₂O₃ phases and presented hardness of 564 HV_0.3 and ~?10 pct porosity. Electrochemical measurements indicated that HVOF coatings exhibit higher corrosion resistance than flame-sprayed ones thanks to the higher amorphous content and lower porosity resulting from the former processing route. Electrochemical impedance spectroscopy results demonstrated that amorphous HVOF Fe₆₀Cr₈Nb₈B₂₄ (at. pct) coatings are interesting to protect mild steels such as the API 5L X80 against corrosion in chloride-rich environments.