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<p>In complex service environments, concurrently improving the wear and corrosion resistance of Fe-based plasma-cladded coatings remains challenging. Here, we establish a layer-resolved thermal-input framework that elucidates the coupling between deposition thermal cycling and post-annealing on microstructural evolution and wear/corrosion performance. Increasing the number of thermal cycles induces grain coarsening and hardness reduction, accompanied by concurrent degradation in both wear and corrosion resistance. Annealing at 673 K effectively relieves microstrain, stabilizes a uniform tribo-oxide film, and increases the fraction of Cr oxides within the passive film; in the middle layer, this yields the lowest wear rate (1.946 × 10<sup>−5</sup>&#xa0;mm<sup>3</sup>/(N&#xa0;m)) and the best corrosion resistance (corrosion rate 1.179&#xa0;mm/y). By contrast, 1023 K/1373 K annealing promotes abundant second-phase precipitation; the resulting interfacial heterogeneity limits the stability of both the tribo-oxide and the passive film, so the overall performance does not surpass that at 673&#xa0;K. This combined thermal-cycle/annealing strategy provides a theoretical basis and practical guidance for the coordinated optimization of gradient Fe-based coatings.</p> Graphical abstract <p></p>

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Modulation of thermal cycles and annealing parameters to enhance wear and corrosion resistance of plasma-cladded Fe-based coatings

  • 期刊论文

  • 发表日期：

    2025年11月9日

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  • Zhonghan Yu,
  • Zhengchen Han,
  • Wenjuan Xing,
  • Changyi Liu,
  • Hongwei Zhao

摘要

In complex service environments, concurrently improving the wear and corrosion resistance of Fe-based plasma-cladded coatings remains challenging. Here, we establish a layer-resolved thermal-input framework that elucidates the coupling between deposition thermal cycling and post-annealing on microstructural evolution and wear/corrosion performance. Increasing the number of thermal cycles induces grain coarsening and hardness reduction, accompanied by concurrent degradation in both wear and corrosion resistance. Annealing at 673 K effectively relieves microstrain, stabilizes a uniform tribo-oxide film, and increases the fraction of Cr oxides within the passive film; in the middle layer, this yields the lowest wear rate (1.946 × 10−5 mm3/(N m)) and the best corrosion resistance (corrosion rate 1.179 mm/y). By contrast, 1023 K/1373 K annealing promotes abundant second-phase precipitation; the resulting interfacial heterogeneity limits the stability of both the tribo-oxide and the passive film, so the overall performance does not surpass that at 673 K. This combined thermal-cycle/annealing strategy provides a theoretical basis and practical guidance for the coordinated optimization of gradient Fe-based coatings.

Graphical abstract