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<p>In this study, FeCrAlY protective coatings were deposited onto lightweight steel substrates using three thermal spray techniques: atmospheric plasma spraying (APS), high-velocity oxy-fuel spraying (HVOF), and cold spraying (CS). The as-deposited microstructures were examined by field emission scanning electron microscopy (FE-SEM), and mechanical performance was assessed through Vickers hardness and adhesion strength measurements. Isothermal oxidation tests were further conducted at 800&#xa0;°C for 1,000&#xa0;h to evaluate long-term oxidation resistance. Mechanical characterization revealed that HVOF and CS coatings significantly improved the surface hardness of lightweight steel, while APS resulted in a decrease. Adhesion testing indicated that HVOF achieved the highest bond strength, whereas APS and CS showed comparable but lower levels, with distinct failure modes associated with each deposition method. Oxidation analysis demonstrated that APS coatings, due to pre-oxides, porosity, and lack of free Al, formed irregular and non-protective oxides, leading to pronounced internal oxidation. In contrast, both HVOF and CS coatings produced dense microstructures capable of sustaining protective alumina scales, which effectively suppressed internal oxidation and retained residual Al even after prolonged exposure. The comparative findings clearly establish that the deposition process strongly influences the balance between mechanical properties and oxidation performance of FeCrAlY coatings. These insights provide important guidelines for optimizing thermal spray processes to achieve superior durability and reliability of lightweight steel in demanding high-temperature environments.</p> Graphical Abstract <p></p>

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The Influence of Deposition Methods on the Microstructural Evolution and Oxidation Behavior at 800 °C of FeCrAlY Coatings on Lightweight Steel

  • 期刊论文

  • 发表日期：

    2025年11月22日

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  • Hyungkwon Park,
  • Hunkwan Park,
  • Hyunwook Cho,
  • Hansol Kwon

摘要

In this study, FeCrAlY protective coatings were deposited onto lightweight steel substrates using three thermal spray techniques: atmospheric plasma spraying (APS), high-velocity oxy-fuel spraying (HVOF), and cold spraying (CS). The as-deposited microstructures were examined by field emission scanning electron microscopy (FE-SEM), and mechanical performance was assessed through Vickers hardness and adhesion strength measurements. Isothermal oxidation tests were further conducted at 800 °C for 1,000 h to evaluate long-term oxidation resistance. Mechanical characterization revealed that HVOF and CS coatings significantly improved the surface hardness of lightweight steel, while APS resulted in a decrease. Adhesion testing indicated that HVOF achieved the highest bond strength, whereas APS and CS showed comparable but lower levels, with distinct failure modes associated with each deposition method. Oxidation analysis demonstrated that APS coatings, due to pre-oxides, porosity, and lack of free Al, formed irregular and non-protective oxides, leading to pronounced internal oxidation. In contrast, both HVOF and CS coatings produced dense microstructures capable of sustaining protective alumina scales, which effectively suppressed internal oxidation and retained residual Al even after prolonged exposure. The comparative findings clearly establish that the deposition process strongly influences the balance between mechanical properties and oxidation performance of FeCrAlY coatings. These insights provide important guidelines for optimizing thermal spray processes to achieve superior durability and reliability of lightweight steel in demanding high-temperature environments.

Graphical Abstract