Abstract
Aluminized carbon steel C45 samples of 0.44 wt.% carbon content were immersed half in a molten salt mixture (NaCl + Na2SO4 with a ratio of 1:3) at a temperature of around 973 K over three different exposure periods: 8, 24, and 72 h. It was observed that a new intermetallic layer (emergent layer) formed at the interface between the steel substrate and the pre-formed intermetallic layers as a result of further outward and inward diffusion of Al, Fe, and C, as indicated by a metallographic study involving SEM combined with EDS spot analysis and elemental analysis. It was also observed that flake-like new phases precipitated in both halves, largely composed of Fe–Al–C–O elementary components, where presumably, the steel C45's high carbon content and the prolonged exposure to high temperatures contributed to further chemical reactions between the elements of HDA specimens and the molten salts’ aggressive Cl and S elements. Moreover, they accelerated the rate of oxidation/corrosion of the hot-dip aluminized C45 steel specimens at high temperatures. Gibbs free energies calculations of some of the corrosion products confirmed the composition of the oxide scale detected experimentally.
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