ABSTRACT
Gas atomized Fe50Cr24Mo21Si2B3 powders were used to form Fe-based alloy coatings by the air plasma spray method. The coatings exhibited high amorphous nature and extremely low porosity of 0.41% in about 200 µm thickness. The Fe-based coating exhibits an average hardness about 1255 Hv. The Fe-based coatings could be potentially applied as functional surface protective coatings.