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Failure Assessment and High-Temperature Corrosion Behavior of Inconel 625 Welds in Simulated K2SO4 + 60% NaCl Boiler Environment

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Abstract

This research investigates the hot corrosion behavior of Inconel 625 similar joints welded using pulsed current gas tungsten arc welding (PCGTAW). Specific emphasis has been given to the microstructural changes at the fusion zone and weld interface while employing two different Ni-Mo-rich fillers (ERNiCrCoMo-1 and ERNiCrMo-4). The microstructure of the weldments was evaluated using scanning electron microscopy (SEM) and optical microscopy (OM) techniques. The weld joints employed with ERNiCrMo-4 filler showed slightly higher strength than that of ERNiCrCoMo-1, and the fractures were found on the base metal regions. The performance of the alloy 625 bi-metallic joints has been ascertained by exposing both cyclic molten salt K2SO4 + 60% NaCl and an air oxidation environment at 700 °C. A thermogravimetric plot was employed to determine the weldment kinetics of corrosion. SEM/EDS systematically examined the oxide scales formed on the weldments, and x-ray diffraction (XRD) was used to identify the phases of the corrosion products. The test results revealed that the corroded samples in the salt condition experienced severe corrosion attacks as compared to air conditions by sulfidation and chlorination. Based on the specific outcomes of this study, ERNiCrMo-4 filler is recommended for joining these similar combinations of welds and it imparts better corrosion resistance at elevated temperatures in simulated boiler environments.

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Acknowledgments

The authors express their sincere gratitude and acknowledge VIT (Deemed-to-be University), Vellore, for granting permission to execute this research work by providing all the required facilities.

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Authors and Affiliations

  1. School of Mechanical Engineering, VIT University, Vellore, 632 014, India

    S. Senthur Prabu & K. Devendranath Ramkumar

  2. Centre for Additive Manufacturing, Chennai Institute of Technology, Chennai, 600069, India

    S. M. Muthu

  3. Department of Mechanical Engineering, Faculty of Engineering and Technology, Jain (Deemed-to-Be University), Bangalore, 562112, India

    S. Sujai & N. Beemkumar

  4. Department of Mechanical Engineering, Er. Perumal Manimekalai College of Engineering, Hosur, 635 117, India

    Elangovan Kariappan

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Prabu, S.S., Muthu, S.M., Sujai, S. et al. Failure Assessment and High-Temperature Corrosion Behavior of Inconel 625 Welds in Simulated K2SO4 + 60% NaCl Boiler Environment. J. of Materi Eng and Perform 32, 11024–11039 (2023). https://doi.org/10.1007/s11665-023-07923-4

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