Characterization of high-temperature abrasive wear of cold-sprayed FeAl intermetallic compound coating

FeAl intermetallic compound coating was prepared by cold spraying using a mechanically alloyed Fe(Al) alloy powder followed by post-spray annealing at 950 °C. The high-temperature abrasive wear test was carried out for the FeAl coating at a temperature range from room temperature to 800 °C. The high-temperature abrasive wear of a heat-resistant stainless steel 2520 was performed for comparison. It was observed that the abrasive wear weight loss of FeAl coating was proportional to wear cycles in terms of sample revolutions at the tested temperatures. It was found that with the increase of the test temperature higher than 400 °C, the wear rate of cold-sprayed FeAl coating decreased with the increase of test temperature, while the wear rate of the heat-resistant steel increased significantly. The results indicate that the high-temperature abrasive wear resistance of the cold-sprayed FeAl intermetallic coating increased with the increase of the wear temperature in a temperature range from 400 to 800 °C. The wear resistance of cold-sprayed FeAl coating was higher than that of heat-resistant 2520 stainless steel under 800 °C by a factor of 3.