A novel
cored wire for producing Fe3Al/WC intermetallic matrix composite (IMC) coating by thermal spraying was developed.
High velocity arc wire spray technology was successfully applied to prepare the Fe3Al/WC IMC coating. The coating composition, microstructure and phases were investigated by energy dispersive X-ray (EDX), X-ray diffraction (XRD), scanning electron microscope (SEM) and image analyzer. Results show that the cored wire arc sprayed iron aluminide IMC coating consists of major phases of Fe3Al (Fe-26Al) and the reinforced hard phases of about 20%WC,W2C and a-Al2O3. As compared with boiler tube steel, the solid particles erosion-
corrosion behavior under different incidence angles and test temperatures of Fe3Al/WC IMC coatings were determined. Results indicate that the erosion-corrosion resistance at elevated
temperature of Fe3Al/WC IMC coating is higher than that of 20g steel. Under oblique impact condition, the relative erosion-corrosion resistance of Fe3Al is 3.14 times than that of 20g steel at temperature of 650℃. It seems that test temperature has great effect on the solid particle erosion behavior of Fe3Al/WC IMC coating. It is found that the Fe3Al/WC coating exhibits typical erosion behavior of ductile materials as increasing test temperature prior to 450℃. With increasing temperature beyond 450℃,the Fe3Al/WC IMC coating turns to exhibit the erosion behavior of brittle material. The erosion-corrosion mechanisms of Fe3Al/WC IMC coatings under elevated temperature were discussed.