Features of arc surfacing of intermetallic alloys of the Fe–Al system on the surface of low-carbon steels

The durability of industrial components is largely determined by the materials they are made of. Often, the materials used must be resistant to wear, corrosion, and high temperatures. Advanced materials, such as high-strength alloy steels, are expensive and have limited weldability, which complicates the restoration of worn components. Fe–Al alloys having high corrosion resistance, wear resistance, and heat resistance at a lower cost are considered as an alternative. The objective of this study is to increase the wear resistance and heat resistance of low-carbon steel components by studying the processes of arc surfacing of iron aluminides and their properties. The study methodology included single-arc and double-arc surfacing using aluminium and steel electrode wires, analysis of the chemical composition of the deposited coatings, their hardness, wear resistance, and heat resistance. The results showed that single-arc surfacing forms alloys based on FeAl₃ and α-Al phases with Fe₂Al₅ and FeAl₃ inclusions, while double-arc surfacing produces alloys more saturated with iron with an α-Fe matrix phase and a Fe₃AlC_x carbide phase. The resulting alloys demonstrate a hardness of up to 58 HRC, a relative wear resistance of up to 2.5 units, and a weight loss of no more than 5 % with an aluminium content of up to 20 %, which indicates their potential for use under high loading conditions. The results confirm the feasibility of using iron aluminides as an inexpensive alternative to expensive coatings, which expands the possibilities for increasing the wear resistance and heat resistance of components in industry.