Two kinds of novel cored wires for producing Fe3Albased intermetallic compound alloy
coatings by using high velocity arc spray technique were developed. The microstructure, chemical composition and phase structure of Fe3Albased coatings were investigated. The tribological properties of thermal spray formed Fe3Albased coatings at
temperature ranging up to 650 ℃ were determined on a pinondisk type
wear tester. Results show that: the
matrix consists of Fe3Al and FeAl phases, which have the average chemical composition of 29%Al(mole fraction); the matrix of Fe3Al/WC
composite coating consists of 26%Al(mole fraction); Fe3Al/WC composite coating exhibits excellent friction reduction and wear resistance at
elevated temperature. The relative wear resistance of Fe3Al/WC composite
Coating is 1.92 times and 9.23 times higher than that of the mild steel at temperature of 450 ℃ and 650 ℃, respectively. The main reasons for wear resistance improvement are the reinforcement of WC/W2C hard particles to the Fe3Al alloy matrix and the formation of selfprotective continuous oxide film on the composite coating surface at elevated temperature.