From foregoing results and discussion, following conclusions can be drawn:
(1) Both Fe–Al coating and Fe–Al/WC composite coatings prepared by high velocity arc spraying and cored wires had typical aspects of thermal sprayed lamellar structure. The majority phases in both coatings were iron aluminide (Fe3Al and FeAl) and α. WC/W2C particles were embedded in the metal matrix of the composite coating.
(2) With adding WC hard particles, the Fe–Al/WC composite coating exhibited higher wear-resistance than Fe–Al coating. But the friction coefficient of both coatings showed little difference.
(3) The coating surface was subjected to alternately tensile stress and compression stress during sliding, and the predominant wear mechanism of the coatings appears to be delamination.
(4) As the load increased, the friction coefficient decreases slightly due to a rise of friction contact temperature and larger areas of oxide films formation on the worn surface, which acts as a solid lubricant. And increasing load causes the maximum shear stress occurring at the deeper position below the surface, thereby aggravating the delamination wear.
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