Corrosion Behavior of Fe-Al Coatings Fabricated by Pack Aluminizing Method

doi:10.1007/s40195-016-0455-5

Abstract

Abstract:

In this study, the two kinds of Fe-Al coatings were fabricated by pack aluminizing on low-carbon steel at different temperatures. The corrosion behavior of the Fe-Al coatings in artificial seawater was investigated by the electrochemical and weight loss techniques. Results show that the thickness of coating layer increases with increasing aluminizing temperature. The coatings exhibit high micro-hardness and good metallurgical bonding with the substrate. In comparison with the steel substrate, the corrosion current density Icorr of the Fe-Al coatings is always lower than that of substrate, about 1/38 or 1/33 after 2 h immersion, and 1/3 or 1/6 for 720 h immersion. As can be seen from the weight loss curve, the Fe-Al coatings show less loss than that of the substrate within 30-day immersion. The corrosion products formed on the surface of the coatings include oxides of Al, Mg, Fe and Ca, and pitting defect has also been found. The Fe-Al coating with higher content of Fe2Al5 has better corrosion resistance.

Key words: Fe-Al coatings, Corrosion, Pack aluminizing, X-ray diffraction

Ning-Ning Li,Min-Zhi Wang,Yong-Sheng Li,Guang Chen,Pei Li. Corrosion Behavior of Fe-Al Coatings Fabricated by Pack Aluminizing Method[J]. Acta Metallurgica Sinica (English Letters), 2016, 29(9): 813-819.

Figures/Tables 14

Table 1 Chemical composition of Q235 low-carbon steel (wt%)

C	Mn	Si	S	P	Fe
0.14-0.22	0.30-0.65	0.30	≦0.050	0.045	Bal.

Table 2 Chemical composition (wt%) of packs with different aluminizing parameters

Materials	Al	Al₂O₃	AlO₃	Temperature(°C)	Time(h)
Condition 1	8.0	87.0	5.0	650	20
Condition 2	8.0	87.0	5.0	750	20

Table 3 Chemical composition of the artificial seawater (g/L)

NaCl	MgCl₂·6H₂O	Na₂SO₄	CaCl₂	KCl	NaHCO₃	KBr	SrCl₂·6H₂O	NaF	H₃BO₃
24.530	11.110	4.090	1.160	0.700	0.200	0.100	0.042	0.003	0.027

Fig. 1 XRD patterns of the Fe-Al coatings fabricated at: a Condition 1, b Condition 2

Fig. 2 SEM morphologies on the cross-section of Fe-Al coatings fabricated at: a Condition 1, b Condition 2

Fig. 3 EDS results of content distribution of Fe-Al coatings fabricated at: a Condition 1, b Condition 2

Fig. 4 Morphologies of micro-hardness indentation of Fe-Al coatings fabricated at: a Condition 1, b Condition 2, c Q235 steel

Fig. 5 Polarization curves of different materials immersed for: a 2 h, b 720 h

Fig. 6 Corrosion current density Icorra and polarization resistance Rp b of different materials

Fig. 7 Weight loss curves of different materials after 30-day immersion

Fig. 8 Morphologies of the corrosion products on Fe-Al coating surface fabricated at: a Condition 1, b Condition 2

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