非晶合金涂层是目前非平衡材料领域的重要研究方向之一，热喷涂制备的非晶涂层既可克服非晶块体材料室温脆性的缺点，又能发挥其优异的防腐耐磨特性，呈现出广阔的应用前景。非晶涂层使役过程中的一个突出问题是易发生分层或局部开裂，最终导致失效。 而在热喷涂过程中产生的孔隙缺陷是其主要原因，亟待解决。本项目拟以超音速火焰喷涂制备的Fe基非晶合金涂层为研究对象，系统地评价与分析孔隙的形成与演化规律以及其与腐蚀行为的内在关联性。主要内容包括：1）涂层中孔隙的类型、含量、尺度与分布等特性的准确测定与定量分析；2）涂层在孔隙缺陷作用下的腐蚀/冲蚀失效行为与机理；3） 热喷涂工艺参数（喷涂能量、涂层厚度、基板温度等）对涂层中孔隙缺陷的形成与演化特性的影响。项目完成后，可揭示非晶涂层中孔隙缺陷对腐蚀的作用机理，为推动高性能非晶涂层的工程化应用提供重要的科学与应用依据。

Bulk metallic glasses exhibit no plastic strain and low toughness at room temperature, which greatly restricts their applications as engineering materials. Amorphous metallic coatings (AMCs) fabricated using the thermal spray method are promising materials due to their good corrosion resistance and mechanical properties with relatively low cost. Fe-based AMCs can be employed in many important industrial fields. However, some local fracture failures of these AMCs have always been reported in severe corrosion and/or abrasive environments. The main failure reason is dominated by the existence of porosities. This defect could be formed inevitably during thermal spray. To obtain the optimum AMCs, the systematic evaluations on the correlation between the porosity defects and corrosion are highly needed. In this project, the Fe-based AMCs fabricated by high velocity oxy-fuel (HVOF) technique are selected to elucidate the defects' intrinsic characteristics and the relationship of the defects with corrosion. The detailed contents contain three aspects: (1) quantitative and accurate measurements and analyses of the existed through porosities and non-through porosities about their important features including type, content, size and distribution; (2) the erosion-corrosion behavior and failure mechanism of AMCs in relation to the porosity defects in aggressive environments; (3) how the spray processes (e.g. spraying momentum, coating thickness, base-plate temperature, etc) affect the formation and evolution of the porosity defects. As these studies are completed, the in-depth understanding of the intrinsic features about the porosities (esp.through-pores) and their correlation with corrosion can be established. It is believed that this project will enhance the practical applications of AMCs in many industrial fields.