Abstract: A novel chromium-free protective coating films based
on a zeolite coating was growing onto a FeCrAlloy metal using in –
situ hydrothermal method. The zeolite film was obtained using in-situ
crystallization process that is capable of coating large surfaces with
complex shape and in confined spaces has been developed. The
zeolite coating offers an advantage of a high mechanical stability and
thermal stability. The physicochemical properties were investigated
using X-ray diffraction (XRD), Electron Microscopy (SEM), Energy
Dispersive X–ray Analysis (EDX) and Thermogravimetric Analysis
(TGA). The transition from oxide-on-alloy wires to hydrothermally
synthesised uniformly zeolite coated surfaces was followed using
SEM and XRD. In addition, the robustness of the prepared coating
was confirmed by subjecting these to thermal cycling (ambient to
550oC).