Abstract: The present study aims to develop composite (amorphous + nanocrystalline) coating using blast furnace (BF) pig iron composition with the help of atmospheric plasma spray process for the first time. The usage of cheap and lean chemical composition of pig iron for the development of economical composite coating on mild steel substrate has led to the improvement in its hardness as well as corrosion resistance in 3.5% NaCl solution. The corrosion resistance of the BF metal composite coating in 3.5% NaCl solution has rivaled that of the heavily alloyed (like Cr, Ni and Mo) 316L stainless steel coating. The as-sprayed coating has been characterized using x-ray diffraction, scanning electron microscope and transmission electron microscope. The improvement in corrosion resistance of composite coating can be attributed to the presence of amorphous, nanocrystalline phase and higher content of P and Si and protective rust phases.
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