A novel method for preparing α-Al2O3 (Cr2O3)/Fe–Al composite coating with high hydrogen isotopes permeation resistance

α-Al2O3 as a preferred material for hydrogen isotopes permeation barrier (HIPB) can effectively prevent hydrogen embrittlement in structural steel and has higher thermal stability. However, its application is limited by the issue that it is hard to prepare α-Al2O3 at relatively low temperature and its formation temperature is too high (>1000 °C) to damage the mechanical properties of structural steel. To overcome this issue, this paper presents a novel method (combining Al electrodeposition, aluminizing, Cr deposition and air oxidation) for the preparation of α-Al2O3 (Cr2O3)/Fe–Al composite coating on 316 L stainless steel for the first time. The formation temperature of α-Al2O3 was successfully reduced to 800 °C. The post-oxidation samples were characterized by SEM, XPS, XRD, EDS and TEM. The results showed that the oxide film was composed of highly crystalline α-Al2O3 and Cr2O3 nanoparticles, where the later were diffusely distributed in the internal α-Al2O3 film. And there was an epitaxial growth relationship between α-Al2O3 and Cr2O3. The low-temperature formation of the α-Al2O3 film was due to the fact that the Cr2O3 nanoparticles formed during the oxidation process acted as templates and nucleation sites, which reduced the nucleation barrier of α-Al2O3. Deuterium permeation tests showed that its deuterium permeation reduction factor (DPRF) was 8892 at 500 °C, which met the standard for practical application.