Abstract The limitations of traditional engineering materials like steels and nickel based alloys can be overcome with spray coatings of intermetallic iron aluminides, such as Fe3Al and FeAl, due to their unique ability to form alumina layer and protect base materials against high temperature corrosion. This review provides necessary background on the development of ductile iron aluminide alloys as engineering structural materials, as wear resistant materials and compares the high temperature oxidation and corrosion resistant properties with several high temperature steels. We then present the status on the Fe3Al and FeAl coatings and sheets obtained by various spray techniques such as atmospheric plasma spraying (APS), vacuum plasma spraying (VPS), high velocity oxy fuel spraying (HVOF) and cold spraying. The spray parameters, the microstructure, and the properties of the coatings are discussed and compared with the bulk properties of iron aluminide alloys. Finally, the paper discusses the application of spray techniques to obtain net shape three dimensional products with intelligent manufacturing techniques and achieve cost effective manufacturing by applying a layer of material as a coating instead of replacing the product obtained after melting, casting, and processing into desired shape.

中文翻译：

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用于高温应用的高级金属间铁铝化物涂层

摘要 Fe3Al 和 FeAl 等金属间铁铝化物喷涂涂层可以克服钢和镍基合金等传统工程材料的局限性，因为它们具有形成氧化铝层和保护基材免受高温腐蚀的独特能力。这篇综述为球墨铸铁铝合金作为工程结构材料、耐磨材料的发展提供了必要的背景，并比较了几种高温钢的高温抗氧化和抗腐蚀性能。然后，我们介绍了通过各种喷涂技术获得的 Fe3Al 和 FeAl 涂层和薄板的状况，例如大气等离子喷涂 (APS)、真空等离子喷涂 (VPS)、高速氧燃料喷涂 (HVOF) 和冷喷涂。喷雾参数、微观结构、讨论了涂层的性能，并与铁铝合金的整体性能进行了比较。最后，论文讨论了应用喷涂技术通过智能制造技术获得净形三维产品，并通过应用一层材料作为涂层而不是代替熔化、浇铸、加工成所需的产品来实现成本效益的制造。形状。