Microstructure, mechanical and electrochemical behavior of magnetron-sputtered carbothermic reduced iron-boride ceramic coatings

In this study, magnetron sputtered carbothermic reduced iron boride (FeB) coatings were developed on grey cast iron (GCI) substrates at different substrate temperatures. The impact of substrate temperature on structural, mechanical, and corrosion behavior was examined for two FeB deposition scenarios: FeB coatings deposited at room temperature (RT) and at 500 degrees C substrate temperature. The evolution of phases and microstructure was studied using XRD and FESEM, respectively. The mechanical properties, creep, deformation behavior, and adhesion strength (scratch test) of the deposited coatings were investigated using nanoindentation at ambient temperature. The highest hardness and Young's modulus of 16 GPa and 231 GPa respectively, were achieved at 500 degrees C due to microstructural enhancement. Potentiodynamic polarization and electrochemical impedance spectroscopy were used to evaluate the corrosion behavior of the coatings. The results show that substrate temperature strongly influences the surface morphology of the coatings, which in turn governs the mechanical and corrosion behavior of the FeB coating. The FeB-coated GCI at 500 degrees C substrate temperature showed higher resistance to scratching, better mechanical properties, and improved corrosion resistance which is attributed to the enhanced adhesive strength, refined microstructure, and formation of protective oxide layers of FeB on the surface of the coatings.