Electro-spark deposition of amorphous Fe-based coatings in vacuum and in argon controlled by surface wettability

[Display omitted] •Amorphous Fe41Co7Cr15Mo14C15B6Y2 coatings obtained by vacuum electrospark deposition.•Arc evaporation accompanies ESD in vacuum and forms thin layer around electrode.•Arc coating provides good wettability and melt flow.•Hard and smooth vacuum-deposited coating ensures good corrosion and tribocorrosion. Amorphous Fe-based coatings deposited on AISI 420S steel by electro-spark deposition in argon at atmospheric pressure and in vacuum using a Fe41Co7Cr15Mo14C15B6Y2 electrode were studied. At the same pulse energy, melt droplets formed during processing in vacuum wet the substrate surface better. This is due to the in situ formation of a thin layer during arc evaporation of the electrode in vacuum prior to the melt transfer. Vacuum-deposited coatings exhibit significantly lower corrosion current and wear rates in seawater.