Fe-Al coatings were deposited on gray cast iron by cold spraying as an exploratory approach for protecting iron relics. The microstructure, deposition efficiency, corrosion property and wear performance of coatings were investigated. Fe-Al coatings completely retained the original composition of mixed powders. Fe particles were surrounded by highly deformed Al particles, and the Fe-50Al coating achieved the highest deposition efficiency (58.6%) and thickness (1.86 mm). Electrochemical tests revealed that the Fe-50Al coating exhibited superior corrosion resistance. Friction and wear tests showed the Fe-50Al coating had the lowest average COF (0.15) owing to its low porosity and distributed soft Al phases. With increasing Al content, the dominant wear mechanism shifted from adhesive to abrasive wear, with oxidative wear present in all coatings.
GroussetSBayleMDauzeresA, et al.Study of iron sulphides in long-term iron corrosion processes: characterisations of archaeological artefacts. Corros Sci2016; 112: 264–275.
2.
SahebMDescostesMNeffD, et al.Iron corrosion in an anoxic soil: comparison between thermodynamic modelling and ferrous archaeological artefacts characterised along with the local in situ geochemical conditions. Appl Geochem2010; 25: 1937–1948.
3.
HuPJiaMLiM, et al.Corrosion behavior of ancient white cast iron artifacts from marine excavations at atmospheric condition. Metals (Basel)2022; 12: 21.
4.
Abdel-KarimAMEl-ShamyAM. A review on green corrosion inhibitors for protection of archeological metal artifacts. Journal of Bio- and Tribo-Corrosion2022; 8: 35.
5.
MohammedEAADe KeersmaeckerMAdriaensA. Inhibition of the corrosion of iron heritage objects after treatment with long-chain monocarboxylic acids in ethanolic solutions. Prog Org Coat2016; 101: 225–232.
6.
BethencourtMFernández-MontblancTIzquierdoA, et al. Study of the influence of physical, chemical and biological conditions that influence the deterioration and protection of underwater cultural heritage. Sci Total Environ2018; 613–614: 98–114.
7.
AshkenaziDInbergALanggutD, et al.Brass–iron couple and brass–iron–wood ternary system of metal objects from the Akko 1 shipwreck (Israel). Corros Sci2016; 110: 228–241.
8.
WangYAnQYangB. Synthesis of UV-curable polyurethane acrylate modified with polyhedral oligomeric silsesquioxane and fluorine for iron cultural relic protection coating. Prog Org Coat2019; 136: 105235.
9.
BiJKLokeZCKLimCKR, et al.Mechanical properties of cold sprayed aluminium 2024 and 7075 coatings for repairs. Aerospace2022; 9: 65.
10.
DykhuizenRCSmithMF. Gas dynamic principles of cold spray. J Therm Spray Technol1998; 7: 205–212.
11.
OyinboSTJenT-C. A comparative review on cold gas dynamic spraying processes and technologies. Manuf Rev2019; 6: 25.
12.
ZhangWLiSZhangX, et al.Research and development on cold-sprayed MAX phase coatings. Coatings2023; 13: 69.
13.
WangYDengNZhouZ, et al.Influence of heating temperature and holding time on the formation sequence of iron aluminides at the interface of Fe/Al coatings. Materials Today Communications2021; 28: 102516.
14.
WangCXueSLuoT, et al.Mechanical shearing-aided one-step compound casting of Al/Fe bimetal. Metallurgical and Materials Transactions B2024; 55: 3626–3638.
15.
MalakarAPancholiVSureshKS. Grain boundary and texture evolution during severe plastic deformation of green Al powder compacts. J Mater Eng Perform2024; 33: 6706–6717.
16.
ChuXChakrabartyRCheH, et al.Investigation of the feedstock deposition behavior in a cold sprayed 316L/Fe composite coating. Surf Coat Technol2018; 337: 53–62.
17.
ZhangCMollaTBrandlC, et al.Cold spraying of mixed metal powders: a modelling framework for predicting deposition efficiency and coating composition. J Therm Spray Technol2025; 34: 1133–1146.
18.
SovaADoubenskaiaMTrofimovE, et al.Cold spray of metal powder mixtures: achievements, issues and perspectives. Trans Indian Inst Met2021; 74: 559–570.
19.
SunCZhouXXieC, et al.Investigating hard/soft combinations of cold spraying by Eulerian approach. Surf Eng2020; 36: 1049–1057.
20.
CincaNListAGärtnerF, et al.Coating formation, fracture mode and cavitation performance of Fe40Al deposited by cold gas spraying. Surf Eng2015; 31: 853–859.
21.
WangYDengNTongZ, et al.The effect of Fe/Al ratio and substrate hardness on microstructure and deposition behavior of cold-sprayed Fe/Al coatings. Materials (Basel)2023; 16: 78.
22.
MaiBLiJZhangY, et al.Investigation of deterioration for large outdoor iron statues relics: a case research of chairman MAO iron statue in Qinghai, China. Coatings2022; 12: 28.
23.
GreveyA-LVignalVKrawiecH, et al.Microstructure and long-term corrosion of archaeological iron alloy artefacts. Heritage Science2020; 8: 57.
24.
ZhaoFFuWBaiL, et al.Metallographic structures and corrosion: cross-section investigation of archaeological iron objects from the Qin-Han Yueyang city site in Xi’an, China. The European Physical Journal Plus2023; 138: 64.
25.
BaoQYangYWenX, et al.The preparation of spherical metal powders using the high-temperature remelting spheroidization technology. Mater Des2021; 199: 109382.
26.
NgC-HYinSLupoiR, et al.Mechanical reliability modification of metal matrix composite coatings by adding al particles via cold spray technology. Surfaces and Interfaces2020; 20: 100515.
27.
ChuXCheHTengC, et al.A multiple particle arrangement model to understand cold spray characteristics of bimodal size 316L/Fe powder mixtures. Surf Coat Technol2020; 381: 125137.
28.
WangH-TLiC-JYangG-J, et al.Cold spraying of Fe/Al powder mixture: coating characteristics and influence of heat treatment on the phase structure. Appl Surf Sci2008; 255: 2538–2544.
29.
WangH-TLiC-JJiG-C, et al.Annealing effect on the intermetallic compound formation of cold sprayed Fe/Al composite coating. J Therm Spray Technol2012; 21: 571–577.
30.
ZhangYWangQChenG, et al.Mechanical, tribological and corrosion physiognomies of CNT-Al metal matrix composite (MMC) coatings deposited by cold gas dynamic spray (CGDS) process. Surf Coat Technol2020; 403: 126380.
31.
MahadeSAweSABjörklundS, et al. Sliding wear behavior of a sustainable Fe-based coating and its damage mechanisms. Wear2022; 500–501: 204375.
32.
ZhangCMollaTBrandlC, et al.Critical velocity and deposition efficiency in cold spray: a reduced-order model and experimental validation. J Manuf Process2025; 134: 547–557.
33.
NorrellTFergusonGAnsellT, et al.Synthesis and corrosion behavior of cold sprayed dual nanoparticle reinforced Al coatings. Surf Coat Technol2020; 401: 126280.
34.
TanYTangJZhaoN, et al.Effect of fluorocarbon polymers on hydrophobicity, wear resistance and corrosion resistance of epoxy resins. Coatings2023; 13: 85.
35.
QianRWangQNiuW, et al.The influence of MoS2 on corrosion behavior of B4C-reinforced aluminium composite coatings by cold spray. JOM2025; 77: 1671–1681.
36.
WuDLiWXuY, et al.Optimizing the corrosion resistance of cold spraying additive manufactured FeCoNiCrMn high entropy alloy: improving particle bonding quality through heat treatment. J Therm Spray Technol2024; 33: 1982–2003.
37.
FanJYunHZhangX, et al.High-Performance pure aluminum coatings on stainless steels by cold spray. Coatings2023; 13: 38.
38.
WenQLiuMZhangZ, et al.Experimental investigation into the friction coefficient of ball-on-disc in dry sliding contact considering the effects of surface roughness. Low Rotation Speed, and Light Normal Load. Lubricants2022; 10: 56.
39.
LiNWangQNiuW, et al. Microstructure and wear behaviors of 17-4 PH stainless steel fabricated by laser cladding with post laser shock peening treatment. Wear2024; 538–539: 205207.
40.
XieLXiongXZengY, et al.The wear properties and mechanism of detonation sprayed iron-based amorphous coating. Surf Coat Technol2019; 366: 146–155.
41.
CaoSLiangJZhouJ, et al.Microstructure evolution and wear resistance of in-situ nanoparticles reinforcing Fe-based amorphous composite coatings. Surfaces and Interfaces2020; 21: 100652.
