| In this paper, the Fe-Al intermetallic coatings has been prepared by Gas Detonation Spraying(GDS) and High Velocity Oxy Fuel Spraying(HVOF), using Fe2Al5 and FeAl powders. It has been studied that the morphologic microstructure changed with the spraying process. Durability experiment of different Fe-Al coatings in pure zinc has been carried out, the zinc-corrosion resistance has been compared and the corrosion mechanism has been discussed. On the base above, a suit of equipment using for simulating the corrosion and abrasion in molten zinc has been made. The results are as follows:(1) Comparing with the original powders, some of FeAl2O4 oxidated layer in the coatings of Fe-Al has been identified in the process of GDS, due to the powder are distributing in the barrel of the long range and resulted in obtained different energy in the DGS process. However, because of the high speed of heated powders when coatings being prepared by HVOF, the oxidation have been avoided, the phases of coatings are homology with the original powders.(2)The Fe-Al coatings with symmetrical microstructure have high zinc-corrosion resistance. Due to the existence of microstructure similarly to the sandwich, the coatings obtained by GDS have better zinc-corrosion resistance than that by HVOF.(3)The corrosion mechanism of Fe-Al coatings obtained by GDS and HVOF has been discussed. Mostly the deliquescent and reactive corrosion happens in the Fe2Al5 coatings obtained by GDS and HVOF, and it is deliquescent corrosion mostly happens in the FeAl coatings.(4)The corrosion and abrasion equipment adopts block-cirque friction pair, whichis made up of abrasion test parts, loading control parts, circumrotate parts, heat up and temperature control parts, circulatory water system parts. The equipment can achieve the simulation and control of the corrosion and abrasion behavior in molten zinc.
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