The Paton Welding Journal, 2026, №08

2026 №08 (04)

DOI of Article 10.37434/tpwj2026.08.05

2026 №08 (06)

---

The Paton Welding Journal, 2026, #8, 41-44 pages

Corrosion resistance of magnetron-sputtered FeAl system coatings

N.V. Vigilianska, K.V. Yantsevych, O.V. Volos, V.G. Zadoya, B.T. Tkachenko

E.O. Paton Electric Welding Institute of the NASU. 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: pewinataliya@gmail.com

Abstract
The paper studies the electrochemical behaviour of FeAl-coatings with different aluminium content deposited by magnetron sputtering in various aggressive environments. The coatings were applied using a modified VU-1B vacuum installation with two targets of iron and aluminium. The coatings were deposited to stainless steel 08Khl8N10T with a thickness of 3 μm. The produced coatings predominantly consist of the FeAl intermetallic phase. The electrochemical behaviour of the coatings was studied in a potentiodynamic mode with 3 % sodium chloride and 10 % sulphuric acid solutions at a temperature of 18–20 °C. The corrosion current of magnetron FeAl-coatings is by an order of magnitude higher in a sodium chloride solution than in sulfuric acid, indicating better corrosion resistance in the latter. It has been shown that the coatings containing 55 at.% aluminium (Fe55Al) exhibit higher corrosion resistance compared to Fe40Al-coatings and even surpass that of 12Khl8N10T stainless steel. The improved resistance of Fe55Al-coatings is attributed to the presence of a single FeAl intermetallic phase and the absence of the α-Fe phase, the presence of which in Fe40Al-coatings corresponds to increasing corrosion processes. The obtained results demonstrate the suitability of using magnetron-sputtered Fe55Al-coatings as a protective layer for components operating in aggressive environments.
Keywords: magnetron sputtering, coating, corrosion resistance, electrolyte

Received: 10.02.20266
Received in revised form: 23.03.2026
Accepted: 28.07.2026

References

1. Zamanzade, M., Barnoush, A., Motz, C. (2016) A review on the properties of iron aluminide intermetallics. Crystals, 6(1), 10. https://doi.org/10.3390/cryst6010010
2. Palm, M., Stein, F., Dehm, G. (2019) Iron aluminides. Annual Review of Mater. Research, 49, 297-326. https://doi.org/10.1146/annurev-matsci-070218-125911
3. Guilemany, J.M., Cinca, N. (2007) High-temperature oxidation of Fe-40Al coatings obtained by HVOF thermal spray. Intermetallics, 15(10), 1384-1394. https://doi.org/10.1016/j.intermet.2007.04.013
4. Cinca, N., Guilemany, J.M. (2012) Thermal spraying of transition metal aluminides: An overview. Intermetallics, 24, 60-72. https://doi.org/10.1016/j.intermet.2012.01.020
5. Borisov, Yu.S., Borisova, A.L., Vigilianska, N.V. et al. (2020) Coatings based on Fe-Al intermetallics produced by the methods of plasma and supersonic air-gas plasma spraying. The Paton Welding J., 7, 29-37. https://doi.org/10.37434/tpwj2020.07.04
6. Senderowski, C., Bojar, Z. (2008) Cas detonation spray forming of Fe-Al coatings in the presence of interlayer. Surface Coatings Technology, 202(15), 3538-3548. https://doi.org/10.1016/j.surfcoat.2007.12.029
7. Vihilianska, N.V., Gryshchenko, O.P., Iantsevitch, C.V. et al. (2022) Corrosion strength of plasma coatings based on composite powders with FeAl intermetallic. The Paton Welding J., 12, 35-39. https://doi.org/10.37434/tpwj2022.12.05
8. Cherif, S.M., Boussigne, K., Roussigne, Y. (2007) Growth and magnetic study of sputtered Fe/Al multilayers. Materials Science and Engineering, 138(1), 16-21. https://doi.org/10.1016/j.mseb.2006.12.009
9. Borisov, Yu.S., Kuznetsov, M.V., Tkachenko, B.T. et al. (2017) Investigation of process of formation of structure and properties in magnetron nanolayer FeAl-coatings. The Paton Welding J., 8, 24-29. https://doi.org/10.15407/tpwj2017.08.04
10. Stönner, T., Hanžel, D., Baretzky, B. et al. (1998) Characterization and oxidation of magnetron sputtered Fe-Al intermetallic alloys. Hyperfine Interactions, 112, 155-160. https://doi.org/10.1023/A:1011017517588
11. Billard, A., Sanchette, F. (2001) Main features of magnetron sputtered aluminium-transition metal alloy coatings. Surface and Coatings Technology, 142-144, 218-224. https://doi.org/10.1016/S0257-8972(01)01197-5
12. Liu, Z., Gao, W., Wang, F. (1998) Oxidation behaviour of FeAl intermetallic coatings produced by magnetron sputter deposition. Scripta Materialia, 39(11), 1497-1502. https://doi.org/10.1016/S1359-6462(98)00360-1
13. (2003) ASM Handbook, Corrosion: Fundamentals, Testing and Protection. Vol. 13A, 1135. ASM International.
14. Sahnenko, M.D., Vyed, M.V., Yaroshok, T.P. (2005) Fundamentals of the theory of corrosion and protection of metals. Kharkiv, NTU KhPI [in Ukrainian].

---

Suggested Citation

N.V. Vigilianska, K.V. Yantsevych, O.V. Volos, V.G. Zadoya, B.T. Tkachenko (2026) Corrosion resistance of magnetron-sputtered FeAl system coatings. The Paton Welding J., 08, 41-44. https://doi.org/10.37434/tpwj2026.08.05

---