Wear-resistant coatings are used in various applications to increase the service life of components. Especially for parts used in aggressive conditions, the surface low-cost base material should be enhanced to have high abrasion and corrosion resistance. For glass molds, coating systems (composition, coating, process) play an important role in contact with molten glass or other aggressive and very hot media. A problem frequently encountered in industrial environment is that after a certain number of cycles melted glass sticks to the grey cast iron mold. To overcome this problem this an Al-based alloy is deposited to a substrate of lamellar grey cast iron by thermal spray processes.

The influence of different heat treatments and the formation of intermetallic phases within the metallic coating were observed. Microstructural characterisations of the coating were analysed using optical and scanning electron microscopy in combination with energy-dispersive x-ray spectroscopy. Mechanical properties like hardness and adhesion of the coatings were measured. Additionally, reactions between coatings and glass melts will be presented.