The increase of commodity prices for classical corrosion protection materials such as WC/Co and Cr3C2/NiCr are leading to significantly increased coating costs. This reduces the competitiveness when compared to other coating technologies such as electroplating, particularly if carbide coatings are representing an over engineered solution for the considered application. A promising economic alternative is the employment of advanced ferrous materials. Fe-base coatings have the potential for very good corrosion protection and favourable wear properties combined with a low cost level due to relatively low priced alloy materials. In this study three different Fe-base materials have been sprayed by liquid and gaseous fuel HVOF spraying and analysed with respect to microstructure, hardness and corrosion resistance. Corrosion tests have been carried out with sulphuric acid as well as artificial seawater.

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