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Improvement of Corrosion Resistance and Structural Integrity of Plasma Sprayed Ni-clad Al Coatings via Pre-oxidation

Abstract

Biomass corrosion is a serious problem that affects the reliability and efficiency of biomass boilers. Ni-based coatings are a potential choice to combat biomass corrosion. In this study, the Ni-clad Al coatings were prepared by air plasma spraying, and the coatings were pre-oxidized in an air atmosphere at 700 °C for 6 h. The corrosion resistance of the as-sprayed and pre-oxidized Ni-clad Al coating exposed to KCl was studied at 600 °C for 168 h. The as-sprayed Ni-clad Al coating showed a much higher corrosion rate due to the porous nature of the coating and faster penetration of corrosion products. The pre-oxidation treatment significantly reduced the corrosion rate of the Ni-clad Al coating. The maximum weight gain of the pre-oxidized Ni-clad Al coating was reduced by 23.5% compared to the as-sprayed Ni-clad coating. After pre-oxidation, multiple NiO layers were formed, and voids were significantly reduced. The corrosion products on the surface of the coating changed from nickel-rich oxides to aluminum-rich oxides after the pre-oxidation treatment.

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Acknowledgments

This work was financially supported by the National Natural Science Foundation of China (Grant No. 52101100), the Natural Science Foundation of Jiangsu Province (Grant No. BK20190915) and the Natural Science Foundation of the Jiangsu Higher Education Institutions of China (Grant No. 21KJB430008).

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Correspondence to Chao Zhang.

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Wu, D., Wu, H., Yuan, Z. et al. Improvement of Corrosion Resistance and Structural Integrity of Plasma Sprayed Ni-clad Al Coatings via Pre-oxidation. J Therm Spray Tech (2022). https://doi.org/10.1007/s11666-022-01451-8

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  • DOI: https://doi.org/10.1007/s11666-022-01451-8

Keywords

  • biomass corrosion
  • KCl corrosion
  • Ni-clad Al coating
  • plasma coating
  • pre-oxidation