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Improvements in Hot Corrosion Behavior of CO2 Laser-Welded Fe-Based A-286 Alloy in an Aggressive Salt Environment by High-Velocity Oxy-Fuel Coating

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Abstract

The current research article examines the high-temperature corrosion properties of the uncoated and HVOF-sprayed CO2 laser-welded Fe-based A-286 alloy in an aggressive three salt mixture (3SM) Na2SO4-5%NaCl-7.5%NaVO3 condition at 850 °C. The structure–property relationship and the performance of two thermal spray powders, Cr3C2-25%NiCr and Ni-20%Cr, on the laser weldments were evaluated by surface and cross-sections analysis. The corrosion kinetics of the coatings was done using the weight change method. The result showed that the uncoated weldment severely suffered in extreme environments. The fine equiaxed structures in the weld zone of the sample are less prone to corrosion attack than the base substrate. The results show that the Cr3C2-25%NiCr-coated sample has better protection of 42% corrosion rate than the Ni-20%Cr and could be attributed to the significant amount of Cr2O3. The Cr3C2-25%NiCr coating follows the parabolic rate law. In the uncoated samples, catastrophic corrosion was due to the oxide dissolution by fluxing by the vanadium and chlorine present in the salt. However, no such phenomenon is noted in the coated samples due to the formation of protective oxide scales.

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Acknowledgments

The authors thank VIT for providing “VIT SEED GRANT” for carrying out this research work. The authors would also like to thank the laboratory in charge of Materials Engineering Technology Laboratory and Advance Materials processing laboratory, VIT- Vellore, for providing all the facilities to perform the research work.

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  1. Centre for Additive Manufacturing and Computational Mechanics, Chennai Institute of Technology, Chennai, India

    S. M. Muthu

  2. Centre for Innovative Manufacturing Research, Vellore Institute of Technology, Vellore, 632014, India

    M. Arivarasu

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Muthu, S.M., Arivarasu, M. Improvements in Hot Corrosion Behavior of CO2 Laser-Welded Fe-Based A-286 Alloy in an Aggressive Salt Environment by High-Velocity Oxy-Fuel Coating. J. of Materi Eng and Perform 32, 847–866 (2023). https://doi.org/10.1007/s11665-022-07138-z

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