Skip to main content
SpringerLink
Log in

A Comparative Study of Cyclic Oxidation and Sulfates-Induced Hot Corrosion Behavior of Arc-Sprayed Ni-Cr-Ti Coatings at Moderate Temperatures

  • Peer Reviewed
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

The cyclic oxidation and sulfates-induced hot corrosion behaviors of a Ni-43Cr-0.3Ti arc-sprayed coating at 550-750 °C were characterized and compared in this study. In general, all the oxidation and hot corrosion kinetic curves of the coating followed a parabolic law, i.e., the weight of the specimens showed a rapid growth initially and then reached the gradual state. However, the initial stage of the hot corrosion process was approximately two times longer than that of the oxidation process, indicating a longer preparation time required for the formation of a protective scale in the former process. At 650 °C, the parabolic rate constant for the hot corrosion was 7.2 × 10−12 g2/(cm4·s), approximately 1.7 times higher than that for the oxidation at the same temperature. The lower parabolic rate constant for the oxidation was mainly attributed to the formation of a protective oxide scale on the surface of corroded specimens, which was composed of a mixture of NiO, Cr2O3, and NiCr2O4. However, as the liquid molten salts emerged during the hot corrosion, these protective oxides would be dissolved and the coating was corrupted acceleratedly.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7

Similar content being viewed by others

References

  1. J. Nicholls, Advances in Coating Design for High-Performance Gas Turbines, MRS Bull., 2003, 28(9), p 659-670

    Article  Google Scholar 

  2. C. Wagner, Theoretical Analysis of the Diffusion Processes Determining the Oxidation Rate of Alloys, J. Electrochem. Soc., 1952, 99(10), p 369-380

    Article  Google Scholar 

  3. Z. Dong, X. Peng, Y. Guan, L. Li, and F. Wang, Optimization of Composition and Structure of Electrodeposited Ni-Cr Composites for Increasing the Oxidation Resistance, Corros. Sci., 2012, 62, p 147-152

    Article  Google Scholar 

  4. D. Young, J. Zurek, L. Singheiser, and W. Quadakkers, Temperature Dependence of Oxide Scale Formation on High-Cr Ferritic Steels in Ar-H2-H2O, Corros. Sci., 2011, 53(6), p 2131-2141

    Article  Google Scholar 

  5. D.W. Yun, S. Seo, H. Jeong, I. Kim, and Y. Yoo, Modelling High Temperature Oxidation Behaviour of Ni-Cr-W-Mo Alloys with Bayesian Neural Network, J. Alloy. Compd., 2014, 587(25), p 105-112

    Article  Google Scholar 

  6. N. Bala, H. Singh, S. Prakash, and J. Karthikeyan, Investigations on the Behavior of HVOF and Cold Sprayed Ni-20Cr Coating on T22 Boiler Steel in Actual Boiler Environment, J. Therm. Spray Technol., 2012, 21(1), p 144-158

    Article  Google Scholar 

  7. S.S. Chatha, H.S. Sidhu, and B.S. Sidhu, High-Temperature Behavior of a NiCr-Coated T91 Boiler Steel in the Platen Superheater of Coal-Fired Boiler, J. Therm. Spray Technol., 2013, 22(5), p 838-847

    Article  Google Scholar 

  8. N. Bala, H. Singh, and S. Prakash, Characterization and High-Temperature Oxidation Behavior of Cold-Sprayed Ni-20Cr and Ni-50Cr Coatings on Boiler Steels, Metall. Mater. Trans. A, 2011, 42(11), p 3399-3416

    Article  Google Scholar 

  9. F. Wang, X. Tian, Q. Li, L. Li, and X. Peng, Oxidation and Hot Corrosion Behavior of Sputtered Nanocrystalline Coating of Superalloy K52, Thin Solid Films, 2008, 516(16), p 5740-5747

    Article  Google Scholar 

  10. X. Ren and F. Wang, High-Temperature Oxidation and Hot-Corrosion Behavior of a Sputtered NiCrAlY Coating with and Without Aluminizing, Surf. Coat. Technol., 2006, 201(1), p 30-37

    Article  Google Scholar 

  11. S. Kamal, R. Jayaganthan, and S. Prakash, Evaluation of Cyclic Hot Corrosion Behaviour of Detonation Gun Sprayed Cr3C2-25%NiCr Coatings on Nickel- and Iron-Based Superalloys, Surf. Coat. Technol., 2009, 203(8), p 1004-1013

    Article  Google Scholar 

  12. N. Bala, H. Singh, and S. Prakash, Accelerated Hot Corrosion Studies of Cold Spray Ni-50Cr Coating on Boiler Steels, Mater. Des., 2010, 31(1), p 244-253

    Article  Google Scholar 

  13. T. Sidhu, S. Prakash, and R. Agrawal, Evaluation of Hot Corrosion Resistance of HVOF Coatings on a Ni-Based Superalloy in Molten Salt Environment, Mater. Sci. Eng. A, 2006, 430(1), p 64-78

    Article  Google Scholar 

  14. H. Singh, D. Puri, and S. Prakash, Some Studies on Hot Corrosion Performance of Plasma Sprayed Coatings on a Fe-Based Superalloy, Surf. Coat. Technol., 2005, 192(1), p 27-38

    Article  Google Scholar 

  15. W. Zanchuk, The Use of Tafaloy 45CT, an Ni-Cr-Ti Alloy, as an Arc Sprayed Corrosion Barrier in High Temperature Sulfurous Environments, Surf. Coat. Technol., 1989, 39–40(Part 1), p 65-69

    Article  Google Scholar 

  16. S. Matthews and M. Schweizer, Optimization of Arc-Sprayed Ni-Cr-Ti Coatings for High Temperature Corrosion Applications, J. Therm. Spray Technol., 2013, 22(4), p 538-550

    Article  Google Scholar 

  17. V. Shukla, R. Jayaganthan, and V. Tewari, Environmental Degradation Behavior of High-Velocity Arc Sprayed FeCrBMnSi Alloy Coatings in a Coal Fired Boiler, Acta Metall. Sin., 2013, 26(5), p 602-612

    Article  Google Scholar 

  18. S. Matthews and M. Schweizer, High-Temperature Oxidation and Smelt Deposit Corrosion of Ni-Cr-Ti Arc-Sprayed Coatings, J. Therm. Spray Technol., 2013, 22(6), p 932-946

    Article  Google Scholar 

  19. G. Calvarin, R. Molins, and A. Huntz, Oxidation Mechanism of Ni-20Cr Foils and Its Relation to the Oxide-Scale Microstructure, Oxid. Met., 2000, 53(1–2), p 25-48

    Article  Google Scholar 

  20. G. Calvarin-Amiri, A. Huntz, and R. Molins, Effect of an Applied Stress on the Growth Kinetics of Oxide Scales Formed on Ni-20Cr Alloys, Mater. High Temp., 2001, 18(2), p 91-99

    Google Scholar 

  21. R. Viswanathan, J. Sarver, and J. Tanzosh, Boiler Materials for Ultra-Supercritical Coal Power Plants-Steamside Oxidation, J. Mater. Eng. Perform., 2006, 15(3), p 255-274

    Article  Google Scholar 

  22. S. Mrowec, On the Mechanism of High Temperature Oxidation of Metals and Alloys, Corros. Sci., 1967, 7(9), p 563-578

    Article  Google Scholar 

  23. S. Saunders, M. Monteiro, and F. Rizzo, The Oxidation Behaviour of Metals and Alloys at High Temperatures in Atmospheres Containing Water Vapour: A Review, Prog. Mater Sci., 2008, 53(5), p 775-837

    Article  Google Scholar 

  24. U. Chatterjee, S.K. Bose, and S.K. Roy, Environmental Degradation of Metals: Corrosion Technology Series/14, CRC Press, Marcel Dekker Inc, New York, 2001

    Google Scholar 

  25. S.J. Geng, F.H. Wang, S.L. Zhu, and W. Wu, Hot-Corrosion Resistance of a Sputtered K38G Nanocrystalline Coating in Molten Sulfate at 900 °C, Oxid. Met., 2002, 57(5-6), p 549-557

    Article  Google Scholar 

  26. L. Shi, Y. Zhang, and S. Shi, The Effect of K2SO4 Additive in Na2SO4 Deposits on Low Temperature Hot Corrosion of Iron-Aluminum Alloys, Oxid. Met., 1992, 38(5–6), p 385-405

    Article  Google Scholar 

  27. T. Sidhu, S. Prakash, and R. Agrawal, Hot Corrosion and Performance of Nickel-Based Coatings, Curr. Sci. Bangalore, 2006, 90(1), p 41-47

    Google Scholar 

  28. T. Sidhu, S. Prakash, and R. Agrawal, Hot Corrosion Performance of a NiCr Coated Ni-Based Alloy, Scripta Mater., 2006, 55(2), p 179-182

    Article  Google Scholar 

  29. R.A. Rapp, Hot Corrosion of Materials: A Fluxing Mechanism?, Corros. Sci., 2002, 44(2), p 209-221

    Article  Google Scholar 

  30. G. Mahobia, N. Paulose, and V. Singh, Hot Corrosion Behavior of Superalloy IN718 at 550 and 650 °C, J. Mater. Eng. Perform., 2013, 22(8), p 2418-2435

    Google Scholar 

  31. J. Goebel, F. Pettit, and G. Goward, Mechanisms for the Hot Corrosion of Nickel-Base Alloys, Metall. Mater. Trans. B, 1973, 4(1), p 261-278

    Article  Google Scholar 

  32. T. Sidhu, S. Prakash, and R. Agrawal, Hot Corrosion Studies of HVOF Sprayed Cr3C2-NiCr and Ni-20Cr Coatings on Nickel-Based Superalloy at 900 °C, Surf. Coat. Technol., 2006, 201(3), p 792-800

    Article  Google Scholar 

  33. K. Tao, X.-L. Zhou, H. Cui, and J.-S. Zhang, Oxidation and Hot Corrosion Behaviors of HVAF-Sprayed Conventional and Nanostructured NiCrC Coatings, Trans. Nonferr. Met. Soc. China, 2009, 19(5), p 1151-1160

    Article  Google Scholar 

  34. K. Tao, X. Zhou, H. Cui, and J. Zhang, Preparation and Properties of a Nanostructured NiCrC Alloy Coating for Boiler Tubes Protection, Mater. Trans., 2008, 49(9), p 2159-2162

    Article  Google Scholar 

  35. L. Shi, Accelerated Oxidation of Iron Induced by Na2SO4 Deposits in Oxygen at 750 °C—A New Type Low-Temperature Hot Corrosion, Oxid. Met., 1993, 40(1-2), p 197-211

    Article  Google Scholar 

Download references

Acknowledgments

The authors appreciate the financial supports from Fundamental Research Funds for the Central Universities (2013B34414, 2013B22814), National Natural Science Foundation of China (50979028), Natural Key Foundation of Jiangsu Provience (BK2011025) and National 973 Plan Project (2015CB057803).

Author information

Authors and Affiliations

  1. College of Mechanics and Materials, Hohai University, Nanjing, 210098, China

    Wenmin Guo, Yuping Wu, Jianfeng Zhang, Sheng Hong, Liyan Chen & Yujiao Qin

Authors
  1. Wenmin Guo
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yuping Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jianfeng Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Sheng Hong
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Liyan Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Yujiao Qin
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Yuping Wu or Jianfeng Zhang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Guo, W., Wu, Y., Zhang, J. et al. A Comparative Study of Cyclic Oxidation and Sulfates-Induced Hot Corrosion Behavior of Arc-Sprayed Ni-Cr-Ti Coatings at Moderate Temperatures. J Therm Spray Tech 24, 789–797 (2015). https://doi.org/10.1007/s11666-015-0222-6

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11666-015-0222-6

Keywords

Search

Navigation