Corrosion behavior and mechanism of Inconel 625 coatings in high-temperature acidic environments for waste incineration applications

Abstract

This study explores the high-temperature corrosion behavior and mechanisms of laser-clad Inconel 625 coatings applied in waste incineration environments. Inconel 625 coatings were deposited on a substrate using laser cladding technology, and corrosion tests were performed in various high-temperature acidic environments. The coatings were analyzed using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and laser confocal microscopy to investigate their microstructure, composition, and corrosion products. The findings indicate that corrosion weight gain was most pronounced in HCl environments at 800 °C and HBr environments at 600 °C, underscoring the critical influence of temperature and acidity on reaction kinetics. Moreover, the corrosion morphology was closely tied to the environment, with distinct patterns observed: pitting in HCl, nodular growth in H2SO4, and cracking and spalling in HF and HBr environments. High temperatures promoted oxidation reactions, resulting in the formation of a dense oxide layer predominantly composed of Cr2O3 and NiCr2O4, which offered some degree of protection. However, pitting and cracking in acidic environments suggested that the protective oxide layer's effectiveness was compromised under extreme conditions. This study provides a comprehensive understanding of the corrosion behavior and mechanisms of Inconel 625 coatings in various acidic environments and high temperatures within waste incineration applications. It offers valuable insights into the impact of temperature and different acidic media on corrosion rates and morphologies, laying the groundwork for predicting the service life and developing protective strategies for these materials in industrial settings.