Effect of Minor Mo Addition on Microstructure and Corrosion Resistance of High-Velocity Air Fuel-Sprayed Fe-Based Amorphous Coatings

In this work, Fe64Nb3B17Si6Cr6Ni4 and Fe60Nb3B17Si6Cr6Ni4Mo4 (at. %) coatings were prepared with a high-velocity air fuel spraying method, and the effects of minor Mo addition on the microstructure, glass formation, and corrosion resistance of the coating were studied. It was found that the Mo addition improves the glass-forming ability of the alloy and a fully amorphous structure with a higher compactness was obtained in the Mo-containing coating. The thermal stability of the coating is enhanced by Mo addition and the onset crystallization temperature was increased by 20 K. In addition, the Mo-containing amorphous coating exhibited higher corrosion resistance than the Mo-free coating. The superior corrosion resistance can be attributed to the increased proportion of protective, stable Cr, Nb, and Mo oxides in the passive film and fewer defects of the Mo-containing coating.