Preparation and characterization of Fe–Al intermetallic layer on the surface of T91 heat-resistant steel

A Fe–Al intermetallic layer was formed on the surface of T91 heat-resistant steel by a molten aluminum hot-dipping and heat diffusion treatment. It is shown that the layer was composed of Al, FeAl3 and Fe2Al5 phases in the as-dipped state while only Fe3Al phase retained after the heat treatment. The intermetallic layer exhibited typical columnar grain structure after the heat treatment, and the thickness of aluminizing layer was increased from 55 μm at 760 °C to around 100 μm at 1050 °C heat treatment. Such a phase composition and grain morphology are favorable for the oxidation and corrosion resistance of T91 steel.