Performance of High-Velocity Oxyfuel-Sprayed Coatings on an Fe-Based Superalloy in Na<SUB>2</SUB>SO<SUB>4</SUB>-60%V<SUB>2</SUB>O<SUB>5</SUB> Environment at 900 °C Part II: Hot Corrosion Behavior of the Coatings

Abstract

NiCrBSi, Cr3C2-NiCr, Ni-20Cr, and Stellite-6 coatings were deposited on an Fe-based superalloy by the high-velocity oxyfuel (HVOF) thermal spray process. The hot corrosion behavior of the coatings in an aggressive environment of Na2SO4-60%V2O5 at 900 °C under cyclic conditions was studied. The thermogravimetric technique was used to establish the kinetics of corrosion. X-ray diffraction, scanning electron microscopy/energy-dispersive x-ray and electron probe microanalysis techniques were used to analyze the corrosion products. Hot corrosion resistances of all the coatings were found to be better than the uncoated superalloy. The Ni-20Cr coating was found to be the most protective, followed by Cr3C2-NiCr coatings. The Ni-20Cr coating had reduced the mass gain by 90% of that gained by the uncoated superalloy. The hot corrosion resistance shown by the Cr3C2-NiCr coating was slightly better compared with the NiCrBSi coating; however, both of the coatings performed better than the Stellite-6 coating. The Stellite-6 coating was the least effective among the coatings studied, but it was still successful in decreasing the mass gain to about one fourth compared with the uncoated superalloy. The formation of oxides and spinels of nickel, chromium, or cobalt may be contributing to the development of hot corrosion resistance in the coatings. This article focuses on the hot corrosion behavior of HVOF coatings. The characterization of these coatings has been presented in part I included in this issue.