Abstract
In this study, FeCrNbBSiC coatings are deposited on aluminum alloy 4042 substrates by wire arc spraying and their microstructure, phase composition, hardness, bonding strength, and thermal conductivity are evaluated in comparison with a commercial 316L stainless steel coating. The FeCrNbBSiC samples were found to have a dense and homogeneous lamellar microstructure with much less oxide inclusions than the stainless steel layer. The iron-based coatings were also much harder, mainly due to their composite structure with amorphous and nanocrystalline phases, and their bonding strength was slightly higher. In thermal conductivity testing, the FeCrNbBSiC layers were found to have thermal insulation properties close to that of conventional (YSZ) TBCs, making them a good candidate for engineering use.
