Microstructure and properties of Fe–Al intermetallic coatings on the low carbon steel synthesized by mechanical alloying

Fe–Al coating was obtained on low carbon steel substrates using mechanical alloying and subsequent heat treatment. Light optical microscopy and a scanning electron microscope equipped with energy dispersive spectroscopy were used to conduct the microstructure characterization. Mechanical properties of the coatings were evaluated by microhardness measurements and wear tests. The corrosion behavior was determined by potentiodynamic polarization measurements in 3.5 % NaCl solution. The results of the mechanical and corrosion tests showed that the hardness and wear resistance of the coatings decreased with increasing the milling time, while increase in the milling time resulted in a significant increase in the thickness, porosity level, and corrosion resistance.