Analyses of the gaseous species in halide-activated cementation coating packs

Abstract

The partial pressures of equilibrium gaseous species in pack-cementation diffusion processes using pure condensed Al(l), Cr(s), and Si(s) metals activated by various halide salts under Ar or reducing environments which contain different amounts of hydrogen have been calculated. The analyses indicate that the presence of hydrogen gas in the system does not significantly alter the equilibrium partial pressures of gaseous species for a pack containing Al at unit activity. In general, the partial pressures of CrCl₂ and SiCl₂ are higher in a chloride-activated pack than in a fluoride-activated pack. Therefore, the codeposition of Cr or Si with Al is possible when a chloride salt is used as the activator with a masteralloy of composition dilute in Al. The addition of hydrogen to the gas phase decreases the partial pressure of Cl₂ and thereby the partial pressures of CrCl₂ and SiCl₂. However, the presence of hydrogen and the formation of hydrogen halides and metal hydrides could increase the kinetics of the transporting processes, particularly for the coatings of Cr and Si. The study also indicates that the vapor pressures for the volatile chlorides of Fe are significantly higher than those for Ni or Co, so that displacement reactions leading to the loss of Fe from the substrate are expected for coating processes involving high halide activities.