This paper reports our investigation on the corrosion resistance and corrosion behaviour of Fe–6·5 wt-%Si atomised powders. Results showed that corrosion resistance was strongly related to powder sizes. When powder sizes were <38 μm, they showed excellent corrosion resistance compared with the larger ones. Analysis suggested that most of the corrosion started from corrosion pits when the powder sizes were >53 μm. Weaker corrosion resistance can be explained by severe Si content heterogeneity and more grain boundaries in the larger sizes atomised powders.
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