The arc spraying process was used to prepare Fe-based amorphous/nanocrystalline coating. The cavitation erosion behaviors of FeNiCrBSiNbW coatings with different surface roughness levels were investigated in distilled water. The results showed that FeNiCrBSiNbW coating adhered well to the substrate, and was compact with porosity of less than 2%. With increasing initial surface roughness, the coatings showed an increase in mass loss of cavitation erosion damage. The amount of pre-existing defects on the initial surface of the coatings was found to be a significant factor for the difference in the cavitation erosion behavior. The cavitation erosion damage for the coatings was a brittle erosion mode. The evolution of the cavitation erosion mechanism of the coatings with the increase of the initial surface roughness was micro-cracks, pits, detachment of fragments, craters, cracks, pullout of the un-melted particle, and massive exfoliations.

The tribological properties of the FePSiB amorphous/nanocrystalline coatings with Cr and Nb additions were investigated in reciprocating mode against tungsten carbide friction coupling with different dry sliding conditions. The wear rates of the FePSiB-based coatings increase linearly with the normal load and sliding speed. The coatings with Cr and Nb promote the formation of successive and compact oxide film on friction surface, which decreases significantly wear rate of the coating. Nano-mechanical characterization done to map the correlation between the elastic properties and wear resistance. The main damage mechanisms of the FePSiB-based coatings under dry friction conditions are abrasion wear, delamination failure and oxidation wear.