SUS316L coatings were sprayed by a high-velocity air fuel (HVAF) system to reduce oxidation and thereby improve the corrosion behavior of stainless coatings. The effects of powder feed rate and particle size on the microstructure, oxide amount and adhesion strength of the coatings were investigated. The corrosion resistance of the coatings was evaluated by conducting salt spray tests. The oxide amount in the coatings sprayed by the HVAF process is below 7 % and adhesion strength is below 34 MPa. In comparison with those of coatings sprayed by a high velocity oxygen fuel (HVOF) system, the oxide amount and adhesion strength are decreased because the particles heated below the melting point of the alloy and insufficient softened in HVAF process. The coatings deposited are original porous, and they become denser through the impinging effect caused by the following sprayed particles. With the increase of powder feed rate and particle size, there is a tendency of reduction in oxides, and an obvious decrease in adhesion strength. Corrosion resistance of the unsealed coatings is insufficient, and this becomes notable with increasing powder feed rate and particle size. The sealed HVAF coating sprayed with the largest particles shows the best corrosion resistance.

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