Intermetallic coatings were produced on pure copper and aluminum-bronze substrates using the powder aluminizing process. The treatments were carried out at 550°C and 600°C during 30, 60, 120, and 180 min. The layers were characterized by optical and scanning electron microscopy (SEM) associated with energy dispersive spectroscopy (EDS), X-ray diffraction (XRD), and wear and hardness testing. The treatments performed at 600°C resulted in larger layer thicknesses compared to those produced at 550°C for both copper and bronze substrates. XRD analysis indicated the presence of intermetallic phases FeAl, FeAl3, and CuAl on aluminum-bronze. The layers produced on the Cu and aluminum-bronze substrates exhibited maximum hardness of approximately 750 HV and 870 HV, respectively. The adhesive wear resistance of all formed layers was higher than those of low-hardness substrates (100 HV in the case of copper and 300 HV for the aluminum-bronze). There were no significant differences in the wear resistances of the layers produced on the same substrate. The abrasion resistance of the aluminum-bronze layers were higher than those of the copper layers, because of the greater hardness of the layers formed on the aluminum-bronze.
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