Comparison of Hot Corrosion Behavior of Ni36Fe34Al17Cr10Mo1Ti2 and Ni34Co25Fe12Al15Cr12W2 Alloys in NaCl-KCl-Na2SO4 Salt

doi:10.1007/s40195-024-01791-0

Abstract

Abstract:

Hot corrosion in molten salt is a complex process, involving both chemical corrosion and electrochemical corrosion. Interfacial reactions and oxide dissolution can also impact the corrosion results. Compared with single component/type salt, multi-component/type hot corrosion leads to more severe degradation, while the multi-component alloys offer potential chances for developing anti-corrosion metallic materials. In this study, we aim to elucidate the hot corrosion behavior and gain a better understanding of the corrosion mechanism of the multi-component alloys under multi-component/type NaCl-KCl-Na₂SO₄ salt. The corrosion behavior of dual-phase Ni₃₆Fe₃₄Al₁₇Cr₁₀Mo₁Ti₂ (HEA-1) and Ni₃₄Co₂₅Fe₁₂Al₁₅Cr₁₂W₂ (HEA-2) alloys was studied within NaCl-KCl-Na₂SO₄ molten salt with mass ratios of 5:5:1 and 5:5:2. After exposure to the salt at 650 °C for 168 h, it was found that the Ni₃₄Co₂₅Fe₁₂Al₁₅Cr₁₂W₂ exhibited better corrosion resistance than Ni₃₆Fe₃₄Al₁₇Cr₁₀Mo₁Ti₂. The improved performance of Ni₃₀Co₂₅Fe₁₂Al₁₅Cr₁₂W₂ alloy was attributed to the Co element, which facilitated the formation of dense oxides scale and enhanced scale adhesion. Alkali chlorides with stronger penetration ability dominated the corrosion process and alkali sulfate further aggravated the corrosion. The primary corrosion mechanisms involved in this process were identified as “electrochemical mechanism” attacking the body-centered cubic structure in the alloys and “active oxidation” causing dissolution of the alloy elements.

Key words: Multi-component salt, Corrosion behavior, Interfacial reaction, Oxide scale, Corrosion mechanism

Xiaoming Liu, Fengyang Quan, Yuan Gao, Shaodong Zhang, Jianbin Wang, Zhijun Wang, Junjie Li, Feng He, Jincheng Wang. Comparison of Hot Corrosion Behavior of Ni₃₆Fe₃₄Al₁₇Cr₁₀Mo₁Ti₂ and Ni₃₄Co₂₅Fe₁₂Al₁₅Cr₁₂W₂ Alloys in NaCl-KCl-Na₂SO₄ Salt[J]. Acta Metallurgica Sinica (English Letters), 2025, 38(2): 205-217.

Figures/Tables 17

Table 1 Main compositions of the HEA-1, HEA-2 and Inconel 625 alloys

Samples	Elements (at.%)
Samples	Al	Cr	Fe	Co	Ni	Mo	W	Ti	Nb
HEA-1	16.9	10.2	33.3	—	36.1	1.6	—	1.9	—
HEA-2	15.2	12.1	11.4	25.1	34.1	—	2.1	—	—
Inconel 625	—	25.6	5.0	—	61.2	5.9	—	—	2.3

Table 2 Detailed experimental method of HEA-1, HEA-2 and Inconel 625 alloys exposed to the NaCl-KCl-Na2SO4 salt at 650 °C for 168 h

Specimen	NaCl:KCl:Na₂SO₄ (wt%)	Surface area (cm⁻²)	Mass change (g)
HEA-1-S1	5:5:1	22.86	1.5667
HEA-1-S2	5:5:2	21.66	1.6191
HEA-2-S1	5:5:1	26.63	0.9868
HEA-2-S2	5:5:2	27.19	0.7288
Inconel 625-S1	5:5:1	12.69	0.2089
Inconel 625-S2	5:5:2	13.98	0.6536

Fig. 1 XRD pattern of the HEA-a and HEA-2 before hot corrosion

Fig. 2 Microstructures of a HEA-1 and b HEA-2 before corrosion test and corresponding element distribution charactered by SEM. The scale bar in the inset was 2 μm

Fig. 3 a SEM micrographs and corresponding element distribution of the HEA-1-S1 alloy at the interface of the oxides scale and alloy matrix, b high-magnification SEM micrographs of the oxides scale and c high-magnification SEM micrographs of the alloy matrix. The element distribution corresponded to the position indicated by the purple line

Fig. 4 a SEM micrographs and corresponding element distribution of the HEA-2-S1 alloy at the interface of the oxides scale and alloy matrix, b high-magnification SEM micrographs of the alloy matrix and c high-magnification SEM micrographs of the oxides scale. The element distribution corresponded to the position indicated by the purple line

Fig. 5 a SEM micrographs and corresponding element distribution of the HEA-1-S2 alloy at the interface of the oxides scale and alloy matrix, b high-magnification SEM micrographs of the alloy matrix and c high-magnification SEM micrographs of the oxides scale. The element distribution corresponded to the position indicated by the purple line

Fig. 6 a SEM micrographs and corresponding element distribution of the HEA-2-S2 alloy at the interface of the oxides scale and alloy matrix, b high-magnification SEM micrographs of the alloy matrix and c high-magnification SEM micrographs of the oxides scale. The element distribution corresponded to the position indicated by the purple line

Fig. 7 XRD pattern of HEA-1 (blue line) and HEA-2 (red line) after hot corrosion in NaCl-KCl-Na2SO4 with ratio 5:5:1 (light color) and 5:5:1 (heavy color)

Fig. 8 Mass change of the HEA-1, HEA-2 and Inconel 625 after exposure to different salt

Table 3 Corrosion performance of difference alloys after hot corrosion comparison

Alloy	Temperature (°C)	Salt	Time (h)	Mass change (mg·cm⁻²)	Reference
AlCoCrFeNi_2.1	450	NaCl-KCl-MgCl₂	24	19	[13]
AlCoCrFeNi_2.1	650	NaCl-KCl-MgCl₂	24	38	[13]
Ni-20Cr-0Si	600	NaCl-KCl-Na₂SO₄-K₂SO₄	144	97.95	[17]
Ni-20Cr-1Si	600	NaCl-KCl-Na₂SO₄-K₂SO₄	144	59.81	[17]
Ni-20Cr-3Si	600	NaCl-KCl-Na₂SO₄-K₂SO₄	144	65.91	[17]
Ni-20Cr-5Si	600	NaCl-KCl-Na₂SO₄-K₂SO₄	144	73.65	[17]
Ni₃₄Co₂₅Fe₁₂Al₁₅Cr₁₂W₂	650	NaCl: KCl: Na₂SO₄	168	27	This work
625-2	700	NaCl-KCl-K₂SO₄	120	34.903	[1]
NiCrMoAl-2	700	NaCl-KCl-K₂SO₄	120	55.812	[1]
CrMnFeCoNi	800	Na₂SO₄ + NaCl	80	60	[28]
Fe₂CoCrNi_0.5	850	NaCl	480	101.7	[26]
Fe₂CoCrNi_0.5Si_0.25	850	NaCl	480	44.5	[26]
Fe₂CoCrNi_0.5Cu_0.25	850	NaCl	480	138.3	[26]
Fe₂CoCrNi_0.5Si_0.25Cu_0.25	850	NaCl	480	78.3	[26]
Al_0.7CoCrFeNi	900	Na₂SO₄ + 25% NaCl	140	92	[16]
Al_1.0CoCrFeNi	900	Na₂SO₄ + 25% NaCl	160	50	[16]
Al_1.3CoCrFeNi	900	Na₂SO₄ + 25% NaCl	160	44	[16]
NiCoCrAl	900	Na₂SO₄ + 25% NaCl	160	55	[16]
NbTaTiV	900	Na₂SO₄ + 25% NaCl	100	287.5	[27]

Fig. 9 Cross-sectional microstructures and corresponding element distribution of a, b HEA-1-S1 and c, d HEA-1-S2

Fig. 10 Cross-sectional microstructure and corresponding element distribution of a, b HEA-2-S1 and c, d HEA-2-S2

Fig. 11 Measured corrosion depth of HEA-1, HEA-2 and Inconel 625 after exposure to different salt. The corrosion depth was measured only below the alloy matrix, which eliminated the interference of oxide layer

Table 4 Standard Gibbs free energy of corresponding chloride formation at 650 °C

Reaction	ΔG (kJ/mol)
Ti + 2Cl₂(g) = TiCl₄	− 588.11
Al + 1.5Cl₂(g) = AlCl₃	− 518.47
Nb + 2.5Cl₂(g) = NbCl₅	− 501.24
Cr + 1.5Cl₂(g) = CrCl₃	− 360.98
Cr + Cl₂(g) = CrCl₂	− 281.46
Fe + 1.5Cl₂(g) = FeCl₃	− 234.59
Co + Cl₂(g) = CoCl₂	− 187.59
Ni + Cl₂(g) = NiCl₂	− 166.81
Mo + Cl₂(g) = MoCl₂	− 150.86
W + Cl₂(g) = WCl₂	− 150.45

Fig. 12 Optical images of the a HEA-1-S1, b HEA-1-S2, c HEA-2-S1, d HEA-2-S2, e Inconel 625-S1, f Inconel 625-S2 alloys after exposure to the NaCl-KCl-Na2SO4 salt at 650 °C for 168 h

Table 5 Phase volume fraction of the HEA-1, HEA-2 and Inconel 625 alloys

Specimen	Phase volume fraction (%)
Specimen	FCC	B2
HEA-1	48.93	51.07
HEA-2	88.24	11.76
Inconel 625	~ 100	—

References 56

[1]	X. Wang, Z. Liu, K. Cheng, Y. Shen, J. Li, Corros. Sci. 221, 111308 (2023)
[2]	J.H. Wang, D.G. Li, T.M. Shao, Corros. Sci. 200, 110247 (2022)
[3]	G. Wang, H. Liu, T. Chen, X. Zhang, H. Li, Y. Yu, H. Yao, Corros. Sci. 189, 109592 (2021)
[4]	M. Li, H. Henein, C. Zhou, J. Liu, J. Mater. Sci. Technol. 174, 133 (2024)
[5]	P. Pan, T. Li, Y. Wang, N. Zhang, H. Chen, Corros. Sci. 203, 110350 (2022)
[6]	R.C. Reed (ed.), The superalloys: fundamentals and applications (Cambridge University Press, Cambridge, 2008)
[7]	G. Han, W. Cho, Oxid. Met. 58, 391 (2002)
[8]	I. Kim, W. Cho, Mater. Sci. Eng. A 264, 269 (1999)
[9]	X. Liu, J. Wang, X. Shi, Y. Jia, L. Liu, J. Li, F. He, Z. Wang, J. Wang, J. Alloys Compd. 963, 171164 (2023)
[10]	J. Wang, H. Jiang, W. Xie, X. Kong, S. Qin, H. Yao, Y. Li, Corros. Sci. 229, 111879 (2024)
[11]	H. Jiang, Z. Ni, J. Wang, D. Qiao, Y. Lv, G. Zhang, L. Liu, Mater. Charact. 201, 112952 (2023)
[12]	M. Li, H. Zhang, Y. Zeng, J. Liu, Acta Mater. 240, 118313 (2022)
[13]	K. Patel, V. Hasannaeimi, M. Sadeghilaridjani, S. Muskeri, C. Mahajan, S. Mukherjee, Entropy 25, 296 (2023)
[14]	P. Cui, Z. Bao, Y. Liu, F. Zhou, Z. Lai, Y. Zhou, J. Zhu, Corros. Sci. 201, 110276 (2022)
[15]	J. Wang, H. Jiang, X. Chang, L. Zhang, H. Wang, L. Zhu, S. Qin, Corros. Sci. 221, 111313 (2023)
[16]	L. Li, J. Lu, X. Liu, T. Dong, X. Zhao, F. Yang, F. Guo, Corros. Sci. 187, 109479 (2021)
[17]	S. Chen, Z. Liu, F. Liu, Coatings 13, 1320 (2023)
[18]	H. He, Z. Liu, W. Wang, C. Zhou, Corros. Sci. 100, 466 (2015)
[19]	X. Li, J. Zou, Q. Shi, M. Dai, H. Yang, Y. Liu, H. Yun, Surf. Coat. Technol. 433, 128119 (2022)
[20]	P. Wang, Y. Wang, F. Cui, X. Yang, A. Pan, W. Wu, J. Alloys Compd. 918, 165602 (2022)
[21]	Q. Cheng, Y. Zhang, X.D. Xu, D. Wu, S. Guo, T.G. Nieh, J.H. Chen, Acta Mater. 252, 118905 (2023)
[22]	J. Wang, Q. Wu, Y. Li, Z. Wang, J. Li, J. Wang, J. Alloys Compd. 916, 165382 (2022)
[23]	Y. Jia, Z. Wang, Q. Wu, Y. Wei, X. Bai, L. Liu, J. Wang, X. Liu, L. Wang, F. He, J. Li, J. Wang, Acta Mater. 262, 119427 (2024)
[24]	Q. Wu, Z. Wang, F. He, Z. Yang, J. Li, J. Wang, J. Mater. Sci. Technol. 128, 71 (2022)
[25]	N. Radhika, N. Noble, A.A. Adediran, Sci. Rep. 14, 5652 (2024) DOI PMID
[26]	Y. Garip, Corros. Sci. 206, 110497 (2022)
[27]	Y. Gao, K. Chong, C. Liu, Y. Cao, D. Wu, Y. Zou, J. Mater. Sci. Technol. 28, 216 (2024)
[28]	Z. Tong, W. Wan, W. Zhou, Y. Ye, J. Jiao, X. Ren, Intermetallics 151, 107710 (2022)
[29]	Y. Zhang, H. Jiang, S. Zhang, Z. Yang, T. Zhang, S. Tian, J. Mater. Sci. Technol. 26, 4887 (2023)
[30]	J. Goebel, F. Pettit, G. Goward, Metall. Trans. 4, 261 (1973)
[31]	J. Cai, C. Gao, P. Lv, C. Zhang, Q. Guan, J. Lu, X. Xu, J. Alloys Compd. 784, 1221 (2019)
[32]	B.P. Mohanty, D.A. Shores, Corros. Sci. 46, 2893 (2004)
[33]	J. Eklund, A. Persdotter, V. Ssenteza, T. Jonsson, Corros. Sci. 217, 111155 (2023)
[34]	D. Fantozzi, V. Matikainen, M. Uusitalo, H. Koivuluoto, P. Vuoristo, Surf. Coat. Technol. 318, 233 (2017)
[35]	R. Jafari, E. Sadeghi, Corros. Sci. 160, 108066 (2019)
[36]	E. Sadeghimeresht, L. Reddy, T. Hussain, N. Markocsan, S. Joshi, Corros. Sci. 132, 170 (2018)
[37]	S.K. Gill, J. Sure, Y. Wang, B. Layne, L. He, S. Mahurin, J.F. Wishart, K. Sasaki, Corros. Sci. 179, 109105 (2021)
[38]	T. Meißner, X. Montero, D. Fähsing, M. Galetz, Corros. Sci. 164, 108343 (2020)
[39]	A. Palacios, M.E. Navarro, Z. Jiang, A. Avila, G. Qiao, E. Mura, Y. Ding, Sol.Energy 201, 437 (2020)
[40]	Xu. Zhang, J. Wan, L. Zhu, H. Zhou, Y. Yang, Met. Mater. Int. 29, 3645 (2023)
[41]	T.A. Badea, D. Batalu, N. Constantin, A. Paraschiv, D. Pătroi, L.C. Ceatra, Materials 15, 4082 (2022)
[42]	J. Wang, D. Li, T. Shao, Surf. Coat. Technol. 440, 128503 (2022)
[43]	P. Zhang, X.H. Li, J. Moverare, R.L. Peng, J. Alloys Compd. 815, 152381 (2020)
[44]	J.S. Meng, M.X. Chen, X.P. Shi, M. Qiang, Trans. Nonferrous Met. Soc. China 31, 2402 (2021)
[45]	M. Srivastava, J.N. Balaraju, B. Ravisankar, C. Anandan, V.W. Grips, Appl. Surf. Sci. 263, 597 (2012)
[46]	Q. Fan, S. Jiang, D. Wu, J. Gong, C. Sun, Corros. Sci. 76, 373 (2013)
[47]	M. Qiao, C. Zhou, Corros. Sci. 63, 239 (2012)
[48]	Q. Fan, S. Jiang, H. Yu, J. Gong, C. Sun, Appl. Surf. Sci. 311, 214 (2014)
[49]	D. Seo, K. Ogawa, Y. Suzuki, K. Ichimura, T. Shoji, S. Murata, Appl. Surf. Sci. 255, 2581 (2008)
[50]	V. Hasannaeimi, A.V. Ayyagari, S. Muskeri, R. Salloom, S. Mukherjee, N.P.J. Mater. Degrad. 3, 16 (2019)
[51]	C. Örnek, D.L. Engelberg, Corros. Sci. 99, 164 (2015)
[52]	C. Örnek, A.H. Ahmed, D.L. Engelberg, Effect of Microstructure On Atmospheric-Induced Corrosion Of Heat-Treated Grade 2205 and 2507 Duplex Stainless Steels. Eurocorr 2012. Dechema, Istanbul, Turkey, 2012. pp. 1-10. https://doi.org/10.13140/RG.2.1.3765.3607
[53]	P. Reccagni, L. Guilherme, Q. Lu, M. Gittos, D.L. Engelberg, Corros. Sci. 161, 108198 (2019)
[54]	D.L. Engelberg, C. Örnek, Corros. Eng. Sci. Technol. 49, 535 (2014)
[55]	Y. Jing, X. Cui, D. Liu, Y. Fang, Z. Chen, A. Liu, X. Wang, G. Jin, Surf. Interfaces 33, 102305 (2022)
[56]	K. Sridharan, T. Allen, Molten Salts Chem. (2013). https://doi.org/10.1016/B978-0-12-398538-5.00012-3

Comparison of Hot Corrosion Behavior of Ni₃₆Fe₃₄Al₁₇Cr₁₀Mo₁Ti₂ and Ni₃₄Co₂₅Fe₁₂Al₁₅Cr₁₂W₂ Alloys in NaCl-KCl-Na₂SO₄ Salt

RichHTML

PDF (PC)

Knowledge

Abstract

Cite this article

share this article

Figures/Tables 17

References 56

Related Articles 15

Recommended Articles

Metrics

Comments

[1]	Jin-Xiu Li, Jun-Xiu Chen, M. A. Siddiqui, S. K. Kolawole, Yang Yang, Ying Shen, Jian-Ping Yang, Jian-Hua Wang, Xu-Ping Su. Enhancing Corrosion Resistance and Antibacterial Properties of ZK60 Magnesium Alloy Using Micro-Arc Oxidation Coating Containing Nano-Zinc Oxide [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(1): 45-58.
[2]	Xingpeng Liao, Jialuo Huang, Zhilin Liu, Jingru Guo, Dajiang Zheng, Pengbo Chen, Fuyong Cao. Degradation Behavior of Zn-Cu Stents with Different Coatings in Sodium Chloride Solution [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(9): 1564-1580.
[3]	You Lv, Yupeng Zhang, Xi Liu, Zehua Dong, Xiaorong Zhou, Xinxin Zhang. Effect of Mn Addition and Heat Treatment on the Corrosion Behaviour of Mg-Ag-Mn Alloy [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(4): 665-677.
[4]	Jingjing Peng, Jing Liu, Shen Zhang, Zhihui Wang, Xian Zhang, Kaiming Wu. Effects of Environmental Factors on Corrosion Behavior of E690 Steel in Simulated Marine Environment [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(4): 678-694.
[5]	Jinchao Jiao, Jin Zhang, Yong Lian, Shengli Han, Kaihong Zheng, Fusheng Pan. Influence of Micro/Nano-Ti Particles on the Corrosion Behavior of AZ31-Ti Composites [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(3): 484-498.
[6]	Haijun Wang, Renju Cheng, Xianhua Chen, Mingbo Yang, Daiyi Deng, Lirui Liu, Yongfeng Zhou, Yanlong Ma, Kaihong Zheng, Fusheng Pan. Interfacial Reaction of Ti6Al4V Lattice Structure-Reinforced VW92 Alloy Matrix Composites [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(3): 570-576.
[7]	Ying Shen, Xianfeng Shan, Iniobong P. Etim, Muhammad Ali Siddiqui, Yang Yang, Zewen Shi, Xuping Su, Junxiu Chen. Comparative Study of the Effects of Nano ZnO and CuO on the Biodegradation, Biocompatibility, and Antibacterial Properties of Micro-arc Oxidation Coating of Magnesium Alloy [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(2): 242-254.
[8]	Gang Niu, Rui Yuan, R. D. K. Misra, Na Gong, Zhi-Hui Zhang, Hao-Xiu Chen, Hui-Bin Wu, Cheng-Jia Shang, Xin-Ping Mao. Effect of La on the Corrosion Behavior and Mechanism of 3Ni Weathering Steel in a Simulated Marine Atmospheric Environment [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(2): 308-324.
[9]	Yanwei Zeng, Peng Xu, Guoqiang Liu, Tianguan Wang, Bing Lei, Zhiyuan Feng, Ping Zhang, Guozhe Meng. ZIF-8 Modified Ce-Sol-gel Film on Rebar for Enhancing Corrosion Resistance [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(12): 2121-2135.
[10]	Zhibin Liu, Guangya Zhu, Wenkai Li, Di Mei, Peihua Du, Yufeng Sun, Shijie Zhu, Shaokang Guan. Effect of Rolling Temperature on the Mechanical Properties and Corrosion Behavior of Mg-Zn-Y-Nd Alloy Thin Sheets [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(10): 1721-1734.
[11]	Yu-Hang Chu, Liang-Yu Chen, Bo-Yuan Qin, Wenbin Gao, Fanmin Shang, Hong-Yu Yang, Lina Zhang, Peng Qin, Lai-Chang Zhang. Unveiling the Contribution of Lactic Acid to the Passivation Behavior of Ti-6Al-4V Fabricated by Laser Powder Bed Fusion in Hank’s Solution [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(1): 102-118.
[12]	W.L. Zhang, W. Li, L.B. Fu, X. Peng, J. Sun, S.M. Jiang, J. Gong, C. Sun. Hot Corrosion Behavior of Hf-Doped NiAl Coating in the Mixed Salt of Na₂SO₄ + K₂SO₄ at 900 °C [J]. Acta Metallurgica Sinica (English Letters), 2023, 36(9): 1409-1420.
[13]	Kai Hu, Lei Zhang, Yuanjie Zhang, Bo Song, Shifeng Wen, Qi Liu, Yusheng Shi. Electrochemical Corrosion Behavior and Mechanical Response of Selective Laser Melted Porous Metallic Biomaterials [J]. Acta Metallurgica Sinica (English Letters), 2023, 36(8): 1235-1246.
[14]	Xian Zhang, Li Gong, Yanpeng Feng, Zhihui Wang, Miao Yang, Lin Cheng, Jing Liu, Kaiming Wu. Effect of Retained Austenite on Corrosion Behavior of Ultrafine Bainitic Steel in Marine Environment [J]. Acta Metallurgica Sinica (English Letters), 2023, 36(5): 717-731.
[15]	Jing Li, Xiaochen Zhang, Haibin Ma, Liangyin Xiong, Shi Liu, Qisen Ren, Zhengzheng Pang. Effect of Silicon and Aluminum Addition on Corrosion Behavior of ODS Iron-Based Alloys in Liquid Lead-Bismuth Eutectic [J]. Acta Metallurgica Sinica (English Letters), 2023, 36(5): 732-744.