Corrosion and wear behaviors of ferrous powder thermal spray coatings on aluminum alloy

Atmospheric plasma spray coating was performed on a cast AA383 Aluminum alloy plate, and this process formed a 170-μm thick spray coating layer by using tentative Fe–C powders with nickel added (up to 14 mass%) or without supplementary nickel. Hardness test, microstructure observation, corrosion and wear tests in engine oil with or without sulfuric acid water solutions added were performed as well. The corrosion performance was dependent upon the nickel content. On the contrary, the wear resistance testing under two engine oil lubrication conditions (with or without sulfuric acid water solution) showed the different tendency instead.