High Performance – Low Costs: Iron Based Coatings with Improved Microstructures for Wear and Corrosion Applications

High and strong fluctuating commodity prices of typical corrosion and wear resistant coatings like WC/Co, Cr₂C₃/NiCr or NiCrBSi are leading to increasing coating costs. Fe-based systems are a cost-effective alternative, if a comparable wear and corrosion resistance can be secured. The objective of this work is the development and the application of Fe-based wear and corrosion-resistant coatings, using optimized material compositions and fine powder materials (5-15 µm) in order to improve the density of the coating on the one hand and reduce the finishing steps by the application of very even coating surfaces on the other hand. Coatings have been analyzed with respect to microstructure, surface properties and coating characteristics such as wear and corrosion behaviour and compared to reference materials 316L, NiCrBSi and galvanic hard chrome. The high potential of Fe-coating systems applied by thermal spraying is demonstrated for the applications the paper- and printing industry and will be transferred to other industry sectors.