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Hot Corrosion of Inconel 625 Overlay Weld Cladding in Smelting Off-Gas Environment

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Abstract

Degradation mechanisms and hot corrosion behavior of weld overlay alloy 625 were studied. Phase structure, morphology, thermal behavior, and chemical composition of deposited salt mixture on the weld overlay were characterized utilizing XRD, SEM/EDX, DTA, and ICP/OES, respectively. Dilution level of Fe in the weldment, dendritic structure, and degradation mechanisms of the weld were investigated. A molten phase formed on the weld layer at the operating temperature range of the boiler, which led to the hot corrosion attack in the water wall and the ultimate failure. Open circuit potential and weight-loss measurements and potentiodynamic polarization were carried out to study the hot corrosion behavior of the weld in the simulated molten salt medium at 873 K, 973 K, and 1073 K (600 °C, 700 °C, and 800 °C). Internal oxidation and sulfidation plus pitting corrosion were identified as the main hot corrosion mechanisms in the weld and boiler tubes. The presence of a significant amount of Fe made the dendritic structure of the weld susceptible to preferential corrosion. Preferentially corroded (Mo, Nb)-depleted dendrite cores acted as potential sites for crack initiation from the surface layer. The penetration of the molten phase into the cracks accelerated the cracks’ propagation mainly through the dendrite cores and further crack branching/widening.

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Acknowledgments

Financial support from the Natural Sciences and Engineering Research Council of Canada (NSERC) and Teck Metals Ltd. is gratefully acknowledged. The first author (Ehsan Mohammadi Zahrani) would like to express his gratitude toward NSERC for providing the prestigious Vanier Canada Graduate Scholarship and the University of British Columbia for providing the Killam Doctoral Fellowship and the Four Years Doctoral Fellowship to him.

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Authors and Affiliations

  1. Corrosion Research Group, Department of Materials Engineering, The University of British Columbia, 309-6350 Stores Road, Vancouver, BC, V6T1Z4, Canada

    E. Mohammadi Zahrani (PhD Candidate) & A. M. Alfantazi (Professor, Associate Dean, Faculty)

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  1. E. Mohammadi Zahrani
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  2. A. M. Alfantazi
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Correspondence to E. Mohammadi Zahrani.

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Manuscript submitted December 5, 2012.

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Mohammadi Zahrani, E., Alfantazi, A.M. Hot Corrosion of Inconel 625 Overlay Weld Cladding in Smelting Off-Gas Environment. Metall Mater Trans A 44, 4671–4699 (2013). https://doi.org/10.1007/s11661-013-1803-y

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