This study evaluates the effects of heat treating on the microstructure, phase composition, and friction and wear behavior of plasma sprayed FeAl coatings. Fe-40Al feedstock powder was deposited on mild steel substrates by atmospheric plasma spraying and the coatings were vacuum annealed at 500, 650, 900, and 1000 °C. An examination of coating cross-sections revealed the presence of diffusion layers in the samples treated at 900 and 1000 °C. XRD analysis indicates that annealing at 650°C facilitates the transformation of Fe(Al) solid solution into FeAl intermetallic phase, resulting in an increase in coating hardness. At higher temperatures, however, Al depletion occurs along with a reduction in hardness. Tribological testing showed that both the friction coefficient and the effects of wear increased after heat treatment.

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