Influence of the size of spraying powders on the microstructure and corrosion resistance of Fe-based amorphous coating

► Fe-based amorphous coatings from different particle sizes of powders were prepared. ► Increasing the particle size will decrease the oxygen content but increase porosity in coating. ► Increasing the particle size will enhance the hydrophobic property of coatings. ► The more hydrophobic is, the better corrosion resistance will be. ► The wettability of coating is closely related with its porosity and oxygen content. The Fe-based amorphous coatings with the composition of Fe48Cr15Mo14C15B6Y2 were successfully sprayed on mild steel substrate by the high velocity oxygen fuel (HVOF) spraying process with different feedstock powder sizes (i.e., powder A: −33+20μm, powder B: −45+33μm, powder C: −55+45μm). The coatings were characterized for its morphology, microstructure and thermal stability by using X-ray diffraction (XRD), differential scanning calorimetry (DSC), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). The corrosion behavior of the coatings in 3.5wt% NaCl solution was studied with potentiodynamic and potentiostatic polarization test. It was found that the particle size of the feedstock powders had a significant influence on microstructure and corrosion resistance of the resultant coatings. The coatings sprayed with the finest powders show the most compact structure; while the coating with the coarser powders exhibits a better corrosion resistance. It is found that the corrosion resistance of the coatings is closely related to the wetting behavior which is affected by the oxygen content and the roughness of coatings. The coatings with hydrophobicity exhibit a better corrosion. The present result demonstrates that the amorphous coatings with hydrophobicity and excellent corrosion resistant are promising for industrial application in marine environment.