Skip to main content
SpringerLink
Log in

Effect of Mo Addition and Water Vapor on the High-Temperature Corrosion Performance of APS Ni-Al-based Coatings

  • ORIGINAL RESEARCH ARTICLE
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

To investigate the influence of Mo addition and water vapor content on the high-temperature corrosion resistance of Ni-Al-based coatings, 0Mo, 5Mo, and 10Mo coatings were deposited by APS thermal spray onto stainless steels. The chlorine-induced corrosion test was conducted in an experimental environment simulating a biomass boiler. The results show that adding the Mo element lowers the coating's ability to resist corrosion without water vapor. The coating is more prone to peeling because Mo prevents the coating from eventually forming a protective oxide layer. Water vapor significantly speeds up the production of oxides and modifies their morphology and structure. The combined effects of Mo and water vapor increase the coating's ability to resist corrosion. The development of thick and protective Ni and Al oxide layers on the coated surface is aided by the acceleration of oxide production by water vapor and the alteration of oxide structure by Mo components.

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
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18

Similar content being viewed by others

Data Availability

Data are available on request from the authors. The data supporting this study's findings are available from the corresponding author upon reasonable request.

References

  1. A.A. Khan, W. de Jong, P.J. Jansens, and H. Spliethoff, Biomass Combustion in Fluidized Bed Boilers: Potential Problems and Remedies, Fuel Process. Technol., 2009, 90, p 21-50.

    Article  CAS  Google Scholar 

  2. M. Oksa, T. Varis, and K. Ruusuvuori, Performance Testing of Iron Based Thermally Sprayed HVOF Coatings in a Biomass-Fired fluidised Bed Boiler, Surf. Coat. Tech., 2014, 251, p 191-200.

    Article  CAS  Google Scholar 

  3. D.L. Wu, K.V. Dahl, F.B. Grumsen, T.L. Christiansen, M. Montgomery, and J. Hald, Breakdown Mechanism of γ-Al2O3 on Ni2Al3 Coatings Exposed in a Biomass Fired Power Plant, Corros. Sci., 2020, 170, p 108583.

    Article  CAS  Google Scholar 

  4. D.L. Wu, K.V. Dahl, T.L. Christiansen, M. Montgomery, and J. Hald, Corrosion Behaviour of Ni and Nickel Aluminide Coatings Exposed in a Biomass Fired Power Plant for Two Years, Surf. Coat. Technol., 2019, 362, p 355-365.

    Article  CAS  Google Scholar 

  5. R. Jafari and E. Sadeghi, High-Temperature Corrosion Performance of HVAF- Sprayed NiCr, NiAl, and NiCrAlY Coatings with Alkali Sulfate/Chloride Exposed to Ambient Air, Corros. Sci., 2019, 160, p 108066.

    Article  CAS  Google Scholar 

  6. J. Eklund, J. Phother, E. Sadeghi, S. Joshi, and J. Liske, High-temperature Corrosion of HVAF-Sprayed Ni-Based Coatings for Boiler Applications, Oxid. Met., 2019, 91, p 729-747.

    Article  CAS  Google Scholar 

  7. F. Wen, Z. Long, Z. Xing, P. Wen, and P. Zhou, Effect of Mo Content on Microstructure and Fatigue Properties of Ni60 Coating Produced by Plasma Cladding, J. Therm. Spray Technol., 2023, 32, p 1389-1405.

    Article  CAS  Google Scholar 

  8. W. Wang, J. Wang, Z. Sun, J. Li, L. Li, X. Song, X. Wen, L. Xie, and X. Yang, Effect of Mo and Aging Temperature on Corrosion Behavior of (CoCrFeNi)100-xMox High-Entropy Alloys, J. Alloy. Comp., 2020, 812, p 152139.

    Article  CAS  Google Scholar 

  9. Y. Behnamian, A. Mostafaei, A. Kohandehghan, B.S. Amirkhiz, D. Serate, and Y. Sun et al., A Comparative Study of Oxide Scales Grown on Stainless Steel and Nickel-Based Superalloys in Ultra-High Temperature Supercritical Water at 800 °C, Corros. Sci., 2016, 106, p 188-207.

    Article  CAS  Google Scholar 

  10. Y. Kawahara, Application of High Temperature Corrosion-Resistant Materials and Coatings Under Severe Corrosive Environment in Waste-to-Energy Boilers, J. Therm. Spray Technol., 2007, 16, p 202-213.

    Article  CAS  Google Scholar 

  11. E. Sadeghi, N. Markocsan, and S. Joshi, Advances in Corrosion-Resistant Thermal Spray Coatings for Renewable Energy Power Plants. Part I: Effect of Composition and Microstructure, J. Therm. Spray Technol., 2019, 28, p 1749-1788.

    Article  CAS  Google Scholar 

  12. A. Zahs, M. Spiegel, and H. Grabke, The Influence of Alloying Elements on the Chlorine-Induced High Temperature Corrosion of Fe-Cr Alloys in Oxidizing Atmospheres, Mater. Corros., 1999, 50, p 561-578.

    Article  CAS  Google Scholar 

  13. R. Bender and M. Schütze, The Role of Alloying Elements in Commercial Alloys for Corrosion Resistance in Oxidizing-Chloridizing Atmospheres. Part II: Experimental Investigations, Mater. Corros., 2003, 54, p 652-686.

    Article  CAS  Google Scholar 

  14. E. Sadeghimeresht, L. Reddy, T. Hussain, M. Huhtakangas, N. Markocsan, and S. Joshi, Influence of KCl and HCl on High Temperature Corrosion of HVAF- Sprayed NiCrAlY and NiCrMo Coatings, Mater. Des., 2018, 148, p 17-29.

    Article  CAS  Google Scholar 

  15. S. Enestam, D. Bankiewicz, J. Tuiremo, K. Mäkelä, and M. Hupa, Are NaCl and KCl Equally Corrosive on Superheater Materials of Steam Boilers?, Fuel, 2013, 104, p 294-306.

    Article  CAS  Google Scholar 

  16. C. Liu, X. Huang, Xu. Ruisi, Y. Mai, L. Zhang, and X. Jie, Microstructure and Properties of Nanocrystalline Ni-Mo Coatings Prepared by Ultrasound-Assisted Pulse Electrodeposition, J. Mater. Eng. Perform., 2021, 30, p 2514-2525.

    Article  CAS  Google Scholar 

  17. A. Niciejewska, A. Ajmal, M. Pawlyta, M. Marczewski, and J. Winiarski, Electrodeposition of Ni-Mo Alloy Coatings from Choline Chloride and Propylene Glycol Deep Eutectic Solvent Plating Bath, Sci. Rep., 2022, 12, p 18531.

    Article  CAS  Google Scholar 

  18. M.J. Lance, K.A. Unocic, J.A. Haynes, and B.A. Pint, Effect of Water Vapor on Thermally-Grown Alumina Scales on Pt-Modified and simple Aluminide Bond Coatings, Surf. Coat. Technol., 2013, 237, p 2-7.

    Article  CAS  Google Scholar 

  19. Wu. Duoli, Wu. Haotian, Z. Yuan, J. Zheng, X. Wei, and C. Zhang, Improvement of Corrosion Resistance and Structural Integrity of Plasma Sprayed Ni-clad Al Coatings via Pre-Oxidation, J. Therm. Spray Technol., 2022, 31, p 2422-2434.

    Article  Google Scholar 

  20. H. Izzuddin, S. Hayashi, S. Yoneda, T. Kogin, E. Ishikawa, and M. Noguchi, Effect of Mo on Corrosion Behavior of Ni20Cr-xMo Alloys in air with NaCl-KCl-CaCl2 Vapor at 570°C, Mater. Corros., 2020, 71, p 1488−1499.

    Article  CAS  Google Scholar 

  21. A. Galerie, S. Henry, Y. Wouters, M. Mermoux, J. Petit, and L. Antoni, Mechanisms of Chromia Scale Failure During the Course of 15-18Cr Ferritic Stainless Steel Oxidation in Water Vapour, Mater. High Temp., 2005, 22, p 105-112.

    Article  CAS  Google Scholar 

  22. J. Ehlers, D.J. Young, E.J. Smaardijk, A.K. Tyagi, H.J. Penkalla, and L. Singheiser et al., Enhanced Oxidation of the 9%Cr Steel P91 in Water Vapour Containing Environments, Corros. Sci., 2006, 48, p 3428-3454.

    Article  CAS  Google Scholar 

  23. X.X. Yu, A. Gulec, C.M. Andolina, E.J. Zeitchick, K. Gusieva, and J.C. Yang et al., In situ Observations of Early Stage Oxidation of Ni-Cr and Ni-Cr-Mo Alloys, Corrosion, 2018, 74, p 939-946.

    Article  CAS  Google Scholar 

  24. J. Peng, X. Fang, Z. Qu, and J. Wang, Isothermal Oxidation Behavior of NiAl and NiAl-(Cr, Mo) Eutectic Alloys, Corros. Sci., 2019, 151, p 27-34.

    Article  CAS  Google Scholar 

Download references

Acknowledgments

This research was funded by the National Natural Science Foundation of China (Grant number 52101100), the General Project of Natural Science Research in Colleges and Universities of Jiangsu Province (Grant number 21KJB430008), and the Qing Lan Project of Yangzhou University (2022).

Author information

Authors and Affiliations

  1. College of Mechanical Engineering, Yangzhou University, Yangzhou, 225127, China

    Duoli Wu, Haotian Wu, Ziyi Yuan, Xinlong Wei & Chao Zhang

Authors
  1. Duoli Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Haotian Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Ziyi Yuan
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Xinlong Wei
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Chao Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Duoli Wu.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wu, D., Wu, H., Yuan, Z. et al. Effect of Mo Addition and Water Vapor on the High-Temperature Corrosion Performance of APS Ni-Al-based Coatings. J Therm Spray Tech 32, 2460–2477 (2023). https://doi.org/10.1007/s11666-023-01672-5

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11666-023-01672-5

Keywords

Search

Navigation