Metal matrix composites (MMCs), combining the unique advantages of two or more constituents, have been recognized as a promising structural material system. Particularly, MMCs reinforced by carbon fibers (CFs) have opened new material design routes towards increased strength-to-weight ratios. Here, we demonstrate a low-cost one-step deposition of CF reinforced stainless steel (CFRSS) composites by twin-wire arc spray on low-alloy steel (LAS) substrates. The CFs are self-assembled and grow coherently, up to 100 s of μm in length, along the splat-domain boundaries with enhanced bonding to their vicinals through partial oxidation. Structural and electrochemical studies reveal a pitting corrosion of the CFRSS layer in aqueous NaCl (3.5 wt.%) electrolyte and the corrosion passivation is apparently larger than that of the LAS substrate. Both the micro- and nano-hardness of the CFRSS layer are improved to over 4 times higher than that of the LAS substrate. These property enhancements indicate that this low-cost one-step process could revolutionize protective coatings on LAS against corrosion and/or erosion under aggressive conditions.

金属基复合材料（MMCs）结合了两种或多种成分的独特优势，被认为是一种很有前途的结构材料系统。特别是，由碳纤维 (CF) 增强的 MMC 为提高强度重量比开辟了新的材料设计路线。在这里，我们展示了通过双线电弧喷涂在低合金钢 (LAS) 基材上低成本一步沉积 CF 增强不锈钢 (CFRSS) 复合材料。CFs 是自组装并连贯生长，长度可达 100 s，沿着 splat-domain 边界，通过部分氧化增强与其邻位的结合。结构和电化学研究表明，CFRSS 层在 NaCl (3.5 wt.%) 水溶液中存在点蚀，腐蚀钝化明显大于 LAS 基材的腐蚀钝化。CFRSS 层的微米和纳米硬度均提高到比 LAS 衬底高 4 倍以上。这些性能增强表明，这种低成本的一步法可以彻底改变 LAS 上的保护涂层，以防止在侵蚀性条件下腐蚀和/或侵蚀。