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Impact of HVOF-Sprayed Ni–Cr and (Co,Ni)O Coatings on the Corrosion Behavior of Cu–Ni–Fe Anodes for Green Aluminum Production

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Abstract

Cu–Ni–Fe alloys are promising O2-evolving anode materials for green Al production but their corrosion-resistance needs to be improved. In the present work, (Co,Ni)O top-coats and Ni–Cr bond-coats are deposited by high-velocity oxy-fuel (HVOF) process on two Cu–Ni–Fe alloys (Cu-rich and Ni-rich). It is firstly shown that (Co,Ni)O materials have a low solubility in the alumina-saturated cryolitic bath at 1000 °C. Then, the impact of the coatings and substrate composition on their oxidation behavior at 1000 °C in air and during Al electrolysis is studied. Although [Ni–Cr/(Co,Ni)O]-coating significantly increases the dry oxidation resistance of Cu–Ni–Fe alloys, the corrosion-resistance of the [Ni–Cr/(Co,Ni)O]-coated Cu–Ni–Fe anodes is low due to the coating detachment during aluminum electrolysis. However, coating Cu–20Ni–15Fe anodes with a single (Co,Ni)O layer increases its corrosion-resistance, prevents it from fluorination, and leads to the rapid formation of a coherent protective NiFe2O4 layer beneath the (Co,Ni)O top-coat. Under the same conditions, the protective NiFe2O4 layer is not formed on the Ni–25Fe–10Cu anode.

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Acknowledgments

The authors wish to thank the Natural Sciences and Engineering Research Council (NSERC) through the Strategic program (STPGP/494283-2016), Prima Québec (Grant R13-13-001), Metal7 and Kingston Process Metallurgy for supporting this work. Vahid Jalilvand wishes to acknowledge a doctoral research scholarship from the Fonds de Recherche du Québec-Nature et Technologies (FRQ-NT). Saeed Mohammadkhani acknowledges the support of the UNESCO Chair Materials for Energy Conversion, Saving and Storage (MATECSS) Excellence Scholarship.

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Authors and Affiliations

  1. INRS- Énergie, Matériaux, Télécommunications, 1650 bd. Lionel Boulet, Varennes, QC, J3X 1S2, Canada

    S. Mohammadkhani, D. Guay & L. Roué

  2. Department Mechanical, Industrial & Aerospace Engineering, Concordia University, 1455 Maisonneuve Blvd W, Montreal, QC, H3G 1M8, Canada

    V. Jalilvand, A. Dolatabadi & C. Moreau

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  1. S. Mohammadkhani
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Correspondence to C. Moreau or L. Roué.

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Mohammadkhani, S., Jalilvand, V., Dolatabadi, A. et al. Impact of HVOF-Sprayed Ni–Cr and (Co,Ni)O Coatings on the Corrosion Behavior of Cu–Ni–Fe Anodes for Green Aluminum Production. Metall Mater Trans B 53, 3543–3556 (2022). https://doi.org/10.1007/s11663-022-02619-x

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