Fe-Al-Cr coatings with different content of Cr additive were prepared on 1045 carbon steel substrates by a laser cladding process. The incorporation of Cr atoms can effectively enhance the corrosion resistance of the coatings. In particular, the Fe-28Al-5Cr laser cladding coating exhibits the best film quality without phase segregation. In addition, the interfacial adhesion between the Fe-28Al-5Cr coating and the 1045 carbon steel substrate is improved. As a result, the Fe-28Al-5Cr laser cladding coating exhibits the best corrosion resistance in a 3.5 wt% NaCl solution under both immersion and electrochemical conditions. However, excessive Cr additive lead to the formation of Al₈Cr₅ in the grain boundaries, resulting in inferior corrosion resistance. Therefore, the new findings demonstrated in this work may inspire the design of high-quality coatings with excellent corrosion resistance.

Fe₃Al is a good magnetic loss absorber for microwave absorption.