Effect of chromium on hot corrosion behavior of arc-sprayed NiCr coatings

In this article,NiCr coatings with chromium content of 13%,27%and 41%were prepared by arc spraying.They were exposed in molten salts(NaCl-Na_(2)SO_(4))at 800℃for 200 hours.The effect of chromium content on the hot corrosion behavior of the coatings was in-vestigated.X-ray diffraction(XRD)and scanning electron microscope with energy dispersion spectrum(SEM-EDS)were used to analyze the phase compositions,morphologies and chemical compositions of the coatings.The results show that NiCr13 coating exhibited the worst hot corrosion resistance due to the low chromium content,which resulted in NiO being the major reaction product.It should be noted that the hot corrosion resistance of NiCr27 coating was better than that of NiCr41 coating.The basic fluxing of Cr_(2)O_(3) lowered its protection during the hot corrosion process and led to the formation of porous Cr_(2)O_(3) on the NiCr41 coating.The molten salts accelerated the oxidation reac-tion resulting in thicker and porous oxide scales formed on the surfaces of coatings.

Hot Corrosion Resistance of TB8 Titanium Alloy after ECAP and Heat Treatment

The metastableβtitanium alloy TB8(Ti-12.76Mo-2.13Nb-2.73A1-0.16Si)was used as the original material,and the secondary processing method combining equal channel angular pressing(ECAP)and heat treatment was adopted.With the help of optical microscope(OM),scanning electron microscope(SEM)and X-ray diffractometer(XRD),the corrosion behavior of TB8 titanium alloy after different secondary processing(800℃/850℃solid solution-520℃aging,ECAP-800℃/850℃solid solution-520℃aging,and800℃/850℃solid solution-ECAP-520℃aging)was studied.The experimental results show that the hot corrosion products of the six samples are similar,mainly Na_(2)Si_(2)O_(5),MoS_(2),TiCl_(2),Ti(SO_(4))_(2),and TiS.Due to the grains of the TB8 titanium alloy treated by 850℃solid solution-ECAP-520℃aging are obviously refined,the surface structure is the most smooth and dense,forming a continuous Al2O3protective film,and the surface defects are the least after corrosion.Its corrosion layer thickness is the lowest(102.3μm),only 36.5%-81.4%of that of other secondary processing titanium alloys.In addition,the corrosion kinetics curves of the six materials all follow parabolic laws,and the minimum corrosion weight gain of the samples after 850℃solutionECAP-520℃aging treatment is 0.7507 mg·mm^(-2),showing better hot corrosion resistance.

Hot corrosion behavior of Ni-xCr-6.8Al based alloys

The hot corrosion behaviors of as-cast and preoxidized Ni-xCr-6.8Al based alloys in the mixture of Na2SO4＋25% NaCl at 873 K were studied. The results show that the mass loss of Ni-xCr-6.8Al based alloys decreases with the increase of Cr content. Preoxidation improves the resistance to corrosion regardless of the concentration of Cr. The kinetics of as-cast Ni-12Cr-6.8Al and Ni-16Cr-6.8Al based alloys fits the parabolic law well, while that of the as-cast Ni-20Cr-6.8Al based alloy fits the power law. The kinetics of all the preoxidized samples obey the logarithmic law. The mechanism of the as-cast alloys can be well explained by the acid-base melting model. The behavior of the preoxidized alloys is found to be mainly determined by the properties of the oxide layer formed during the preoxidation to a large extend.

Hot corrosion characteristics of Ni-20Cr-18W superalloy in molten salt

The hot corrosion behavior of a Ni?20Cr?18W (mass fraction, %) superalloy in the mixture of 75%Na 2 SO 4?25%NaCl melts at 700 and 800 °C was studied. The results demonstrate that the alloy suffers from serious hot corrosion attack in the mixture molten salt. Meanwhile, the degradation of the substrate accelerates with increasing the corrosion temperature. The corrosion layer has an obvious duplex microstructure, and the Cr-depletion zone is detected obviously nearby the inner corrosion layer. The main corrosion products at 700 and 800 °C are almost the same and mainly include NiO, Cr2O3and Ni3S2, but a trace amount of NiCrO2 is detected at 800 °C for 20 h. The hot corrosion mechanism and formation mechanism of corrosion scales of the Ni?20Cr?18W superalloy in the molten salt are proposed.

Cyclic oxidation and hot corrosion of Al_2O_3 or Y_2O_3-dispersed low-temperature chromizing coating

Chromium coatings with and without Al_2O_3 or Y_2O_3 particles were prepared by chromizing the as-deposited Ni-film with and without Al_2O_3 or Y_2O_3 particles using a conventional pack-cementation method at 800 ℃. The cyclic oxidation at 800 ℃ and hot corrosion in molten 75% Na2SO4＋25% NaC1 at 800 ℃ of the three different chromizing coatings were investigated. The effects of Al_2O_3 or Y_2O_3 on the cyclic oxidation and hot corrosion behavior of the chromizing coatings were discussed. Microstructure results show that the codeposited Al_2O_3 or Y_2O_3 particles significantly retard the grain growth of the chromizing coating, which increases the cyclic oxidation and hot corrosion resistance of the chromizing coatings, due to the more rapid formation of purer and denser chromia scnle

Oxidation and hot corrosion of electrodeposited Ni-7Cr-4Al nanocomposite

A Ni-7Cr-4Al（mass fraction, %） nanocomposite was fabricated by co-electrodeposition of Ni with Cr（40 nm） and Al（100 nm） nanoparticles from a nickel sulfate bath, and its oxidation at 800 °C in air and hot corrosion under molten 75% Na2SO4 ＋ 25% Na Cl salts（mass fraction） at 750 °C were investigated. For comparison, Ni-11 Cr nanocomposite and Ni-film were also investigated in order to elucidate the effect of Cr nanoparticles. The results indicate that Cr and Al nanoparticles are dispersed in the electrodeposited nanocrystalline Ni grains（in size range of 20-60 nm）. Ni-7Cr-4Al nanocomposite exhibits a dramatically increased oxidation resistance compared with Ni-11 Cr nanocomposite and Ni-film due to the fast formation of alumina scale, which also improves its hot corrosion resistance under molten 75% Na2SO4 ＋ 25% Na Cl salts.

HOT CORROSION BEHAVIOR OF Ni-BASED SUPERALLOYS WITH HIGHER Cr CONTENTS -PART Ⅱ.MECHANISM OF HOT CORROSION BEHAVIOR

Based on the experimental results in the previous paper, the mechanism of the hot corrosion behavior of alloy system Ni-16Cr-gAl-2W- 1Mo-4Co-(0～4)Ti-f(0 ～ 4)Ta-(0～4)Nb (in at%) is investigated. In the Ti and Nb-rich corners, hot corrosion is controlled by the basic fluxing mechanism, and a dense and protective surface scale is formed which results in the better hot corrosion resistance for the alloys in these regions. While in the Ta-rich comer,the basic and acidic mechanisms function alternatively, which results in the catastrophic corrosion by forming the porous and non-protective scale, so the alloys in this region show poor hot corrosion resistance. In addition, the concept of 'effective chromium content' seemed to give a correct prediction of the hot corrosion resistance of such alloy systems.

HOT CORROSION BEHAVIOR OF Ni-BASED SUPERALLOY WITH HIGH Cr CONTENTS -PART 1.EXPERIMENTAL STUDY

A systematic study of the effects of Ti, Ta and Nb on the hot corrosion behavior of alloy system Ni-16Cr-gAl-2W-1Mo-4Co-(0～4)Ti-(0～4)Ta-(0～4)Nb (at%) was conducted. The results showed that, in certain compositional regions, the hot corrosion resistance in 75% NaiSO4+25%NaCl molten salt of the expermental alloys was similar to that of IN738LC alloy. The hot corrosion property balances with other properties, which provides the basis for selecting alloy compositions to develop single crystal superalloys of high performance hot corrosion resistance.

HOT CORROSION OF A PLASMA SPRAYED CoNiCrAlTaSiY COATING

Hot corrosion(HC) of the APS(atomospheric plasma spraying)CoNiCrAlTaSiY coating on a nickel-base superalloy GH864 has been studied. The effect of laser-treatment on hot corrosion resistance was also examined.It was shown that CoNiCrAlTaSiY coating had superior properties in resistance to hot corrosion due to the readiness of the formation of a protective Cr2O3 scale on the coating surface.A model for the mechanism of hot corrosion of this coating has been suggested. Hot corrosion resistance of this coating was significantly increased by the laser treatment simply because the surface of the as sprayed coating was densified by the high power laser beam.

Effect of Co on oxidation and hot corrosion behavior of two nickel-based superalloys under Na_(2)SO_(4)-NaCl at 900℃

Nickel-based superalloys with and without Co by partial replacement of W were prepared using double vacuum melting.A comparison of the oxidation in air and hot corrosion behaviors under molten 75 wt.%Na2 SO4+25 wt.%NaCl at 900℃were systematically investigated.The results showed that partial replacement of W with Co promoted the formation of chromia scale and consequently decreased the oxidation rate.Besides,the addition of Co also retarded the internal oxidation/nitridation of Al and consequently promoted the growth of Al_(2) O3 scale,which further decreased the scaling rate and improved the adhesion of scale.Moreover,the addition of Co also further improved the hot corrosion resistance under molten Na2 SO4-NaCl salts.

Microstructure and hot corrosion behavior of Al-Ce-Y coatings on DZ125 nickel-based alloy prepared by pack cementation process

In order to improve the hot corrosion resistance of DZ125 alloy,Ce-Y modified aluminum coatings were prepared on DZ125 alloy by pack cementation process at 950°C for 2 h.The microstructure,phase constitution and formation mechanism of the coatings were investigated.The hot corrosion behaviors of DZ125 alloy and the coatings in molten salt environment of 25%K2SO4+75%Na2SO4(mass fraction)at 900°C were studied.Results show that the obtained Al-Ce-Y coatings were mainly composed of Al3Ni2,Al3Ni and Cr7Ni3,with a thickness of about 120μm.After hot corrosion test,DZ125 alloy suffered catastrophic hot corrosion and serious internal oxidation and internal sulfidation arose.Two layers of corrosion products formed on surfaces of DZ125 alloy,including the outer layer consisting of Cr2O3 and NiCr2O4,and the inner layer of Al2O3,Ni3S2 and Ni-base solid solution.After being coated with Al-Ce-Y coating,the hot corrosion resistance of DZ125 alloy is improved notably,due to the formation of a dense scale mainly consisting of Al-rich Al2O3 in the coating layer.

Improving hot corrosion resistance of aluminized TiAl alloy by anodization and pre-oxidation

To shield TiAl alloy from hot corrosion attack,a compact protective coating was fabricated by the combination of aluminizing,anodization and pre-oxidation.The hot corrosion behavior of the coated-TiAl specimen was investigated in the mixture salt consisting of 75 wt.%Na2SO4 and 25 wt.%NaCl at 700°C.Results indicated that the anodization and pre-oxidation were beneficial to the generation of Al2O3 layer,which could act as a diffusion barrier to prevent the molten salts and oxygen from diffusing into the alloy during exposure to a hot corrosion environment while the aluminizing coating could provide sufficient aluminum source to support the continuous formation of Al2O3 layer.Moreover,the internal stress of the coating was reduced due to the formation of a gradient coating consisting of TiAl3 and TiAl2.

Effect of Yttrium on Microstructure and Hot Corrosion Preformance of Laser Clad Co-Based Alloy

The structure of the yttrium modified Co-base alloy layers formed by laser cladding on 2Cr13 and 1Cr18Ni9Ti steel surfaces and its hot corrosion performance have been investigated systematically.The re- sults show that the Y-containing cobalt base clad alloy has a finer microstructure and higher corrosion re- sistance to the salt mixture of 75% Na_2SO_4+25%NaCl at high temperature.The unique properties are ob- tained with addition of 0.875% Y for the formation of a continuous and compact oxide scale.The compact scale may act as a barrier for the inward diffusion of oxygen and sulphur and also for the outward diffusion of alloying elements.

Microstructural analysis and hot corrosion behavior of HVOF-sprayed Ni–22Cr–10Al–1Y and Ni–22Cr–10Al–1Y–SiC(N) coatings on ASTM-SA213-T22 steel

The present paper deals with the investigation of microstructure and high-temperature hot corrosion behavior of high-velocity oxy fuel(HVOF)-produced coatings. Two powder coating compositions, namely, Ni22Cr10Al1Y alloy powder and Ni22Cr10Al1Y(80 wt%;microsized)–silicon carbide(SiC)(20 wt%;nano(N)) powder, were deposited on a T-22 boiler tube steel. The hot corrosion behavior of bare and coated steels was tested at 900°C for 50 cycles in Na2SO4–60 wt%V2O5 molten-salt environment. The kinetics of corrosion was established with weight change measurements after each cycle. The microporosity and microhardness of the as-coated samples have been reported. The X-ray diffraction,field emission-scanning electron microscopy/energy dispersive spectroscopy, and X-ray mapping characterization techniques have been utilized for structural analysis of the as-coated and hot-corroded samples. The results showed that both coatings were deposited with a porosity less than2%. Both coated samples revealed the development of harder surfaces than the substrate. During hot corrosion testing, the bare T22 steel showed an accelerated corrosion in comparison with its coated counterparts. The HVOF-sprayed coatings were befitted effectively by maintaining their adherence during testing. The Ni22Cr10Al1Y–20 wt%SiC(N) composite coating was more effective than the Ni–22Cr–10Al–1Y coating against corrosion in the high-temperature fluxing process.

Hot corrosion of modified Ti_3Al-based alloy coated with thin Na_2SO_4 film at 910 and 950℃ in air

The hot corrosion behaviour of a modified Ti3Al-based alloy under thin Na2SO4deposit film was investigated at910and950°C in air.The corrosion product was identified by XRD and its morphologies on the surface and cross-section were observed bySEM.The alloy suffered from considerable hot corrosion attack.The mass gain versus time curves obtained by TGA exhibited tworegions of different kinetics.The whole corroded layer consisted of loose and porous mixture oxides of TiO2,Nb2O5and Al2O3.Numerous small nodules of corrosion product were observed.An illustrative schematic was established to describe the formationprocess of such nodules.It seemed that the refractory oxides played a significantly important role in determining the development ofhot corrosion attack.

Effect of Sputtered TiAlCr Coatings on Oxidation and Hot Corrosion Resistance of Ti-24Al-14Nb-3V

The effect of sputtered Ti-50Al-10Cr and Ti-50A1-20Cr coatings on both isothermal and cyclic oxidation resistance at 800-900℃ and hot corrosion resistance at 850℃ of Ti-24Al-14Nb-3V was investigated. Results indicated that Ti-24Al-14Nb-3V alloys exhibited poor oxidation resistance due to the formation of Al2O3+TiO2+AlNbO4 mixed scales in air at 800-900℃ and poor hot corrosion resistance due to the spoliation of scales formed in Na2SO4+K2SO4 melts at 850℃. Both Ti-50Al-10Cr and Ti-50Al-20Cr coatings remarkably improved the oxidation and hot corrosion resistance of Ti-24Al-14Nb-3V alloy.

Oxidation and Hot Corrosion of Gradient Thermal Barrier Coatings Prepared by EB-PVD

The performances of gradient thermal barrier coatings (GTBCs) produced by EB-PVD were evaluated by isothermal oxidation and cyclic hot corrosion (HTHC) tests. Compared with conventional two-layered TBCs, the GTBCs exhibite better resistance to not only oxidation but also hot-corrosion. A dense Al2O3 layer in the GTBCs effectively prohibites inward diffusion of O and S and outward diffusion of Al and Cr during the tests. On the other hand, an "inlaid" interface, resulting from oxidation of the Al along the columnar grains of the bond coat, enhances the adherence of AI2O3 layer. Failure of the GTBC finally occurred by cracking at the interface between the bond coat and AI2O3 layer, due to the combined effect of sulfidation of the bond coat and thermal cvcling.

Oxidation and Hot Corrosion Behavior of a Composite Coating System

The oxidation and hot corrosion behavior of Co-Ni-Cr-AI-Ta-Y coating produced by magnetron sputtering with and without enamel coating has been investigated in air at 900℃ and in molten 75 wt pct NaCl+25 wt pct Na2SO4 at 850℃. The results show that the enamel coating possesses good hot corrosion resistance in the molten salts, in comparison with the sputtered Co-Ni-Cr-AI-Ta-Y coating. In the hot corrosion test, breakaway corrosion did not occur on the samples with enamel coating and the composition of enamel coating did not significantly change either. The oxidation resistance of the sputtered coating, which offers good adhesion, can be improved by the enamel coating.

Oxidation and hot corrosion behaviors of Nb−Si based ultrahigh temperature alloys at 900℃

Oxidation and hot corrosion behaviors at 900 ℃ of Nb-Si based ultrahigh temperature alloys were investigated. Both oxidation and hot corrosion kinetics curves of the alloy involve an initial parabolic stage and a later rapid linear stage. In the initial oxidation stage(1-50 h), a thin and continuous scale is formed on the alloy surface, while severe pest degradation phenomenon is observed in the linear oxidation stage. Compared with oxidation of the alloy in static air, a linear hot corrosion stage happens earlier and catastrophic scale disintegration occurs after hot corrosion for 20-100 h, demonstrating that molten salts(Na2SO4 and NaCl) could significantly accelerate the oxidation process of the alloy. STEM results indicate that the corroded scale consists mainly of TiO2, Nb2O5, TiNb2O7, amorphous silicate and NaNbO3.

Microstructure and hot corrosion resistance of Si-Al-Y coated TiAl alloy

In order to obtain a high-performance surface on TiAl alloy that can meet the requirements in hot corrosion environment,Si-Al-Y coatings were fabricated by pack cementation process at 1050℃for 4 h.Corrosion behaviors of the TiAl alloy with and without Si-Al-Y coatings are compared to illustrate the factors and corresponding mechanism in molten salt environment of 25 wt%K2SO4 and 75 wt%Na2SO4 at 900°C.The obtained Si-Al-Y coating was mainly composed of a TiSi2 outer layer,a(Ti,X)5Si4 and(Ti,X)5Si3(X represents Nb or Cr element)middle layer,a TiAl2 inner layer and a Al-rich inter-diffusion zone.The inter-phase selective corrosion containing corrosion pits extending alongα2 phase from lamellar interfaces in hot corrosion tested TiAl alloy was observed.However,by being coated with Si-Al-Y coating,the hot corrosion performance of TiAl alloy was improved remarkably.