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KCl-Induced High-Temperature Corrosion Behavior of HVAF-Sprayed Ni-Based Coatings in Ambient Air
Open accessAbstract
KCl-induced high-temperature corrosion behavior of four HVAF-sprayed Ni-based coatings (Ni21Cr, Ni5Al, Ni21Cr7Al1Y and Ni21Cr9Mo) under KCl deposit has been investigated in ambient air at 600 °C up to 168 h. The coatings were deposited onto 16Mo3 steel—a widely used boiler tube material. Uncoated substrate, 304L and Sanicro 25 were used as reference materials in the test environment. SEM/EDS and XRD techniques were utilized to characterize the as-sprayed and exposed samples. The results showed that the small addition of KCl significantly accelerated degradation to the coatings. All coatings provided better corrosion resistance compared to the reference materials. The alumina-forming Ni5Al coating under KCl deposit was capable of forming a more protective oxide scale compared to the chromia-forming coatings as penetration of Cl through diffusion paths was hindered. Both active corrosion and chromate formation mechanisms were found to be responsible for the corrosion damages. The corrosion resistance of the coatings based on the microstructure analysis and kinetics had the following ranking (from the best to worst): Ni5Al > Ni21Cr > Ni21Cr7Al1Y > Ni21Cr9Mo.
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“However, the combustion of biomass and waste is well-known to result in a corrosive environment within the boiler due to the formation of, e.g., alkali salts and high levels of H2O(g), which accelerate the degradation of various components in the boiler, such as the superheater tubes (SH).1−12”
From High-Temperature Corrosion Behavior of Superheater Materials at 600 °C: Insights from Laboratory and Field Exposures (2025) · cites this paper as [5]
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References 44 · Cited by 37
Metadata
- Authors
- Jafari, R., Sadeghimeresht, E., Farahani, T. S., Huhtakangas, M., Markocsan, N., & Joshi, S.
- Affiliations
- Tarbiat Modares University (IR)
- University West (SE)
- Venue
- Journal of Thermal Spray Technology
- Published
- 2018-01-02
- Volume
- 27
- Issue
- 3
- Pages
- 500-511
- ISSN
- 1059-9630 (ISSN-L)
- 1544-1016
- OpenAlex
- W2781506647
- Cited by
- 37
- References
- 44
- Citations by year
- 2026: 4 · 2025: 2 · 2024: 3 · 2023: 8 · 2022: 5 · 2021: 4 · 2020: 1 · 2019: 8 · 2018: 2
- FWCI
- 3.05
- Type
- journal article
- Language
- en
- Open access
- hybrid
- doi.org
- Locations
- Journal of Thermal Spray Technology (publishedVersion, cc-by)
- Diva portal (Dalarna University Library) (submittedVersion, other-oa)
- Topics
- Physical Sciences › Materials Science › Surfaces, Coatings and Films › High-Temperature Coating Behaviors
- Physical Sciences › Engineering › Mechanical Engineering › High Temperature Alloys and Creep
- Physical Sciences › Engineering › Mechanical Engineering › Surface Treatment and Coatings
- Keywords
- high-temperature corrosion, HVAF spraying, Ni-based coatings, 16Mo3 steel, chromia scale, alumina scale, active corrosion, chloride penetration
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- CoChat. (2026). Citation check: KCl-Induced High-Temperature Corrosion Behavior of HVAF-Sprayed Ni-Based Coatings in Ambient Air. https://app.cochat.ai/papers/10.1007/s11666-017-0684-9
- The paper
- Jafari, R., Sadeghimeresht, E., Farahani, T. S., Huhtakangas, M., Markocsan, N., & Joshi, S. (2018). KCl-Induced High-Temperature Corrosion Behavior of HVAF-Sprayed Ni-Based Coatings in Ambient Air. Journal of Thermal Spray Technology. https://doi.org/10.1007/s11666-017-0684-9
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Contains information from the Semantic Scholar Academic Graph Datasets, made available under the ODC Attribution License (ODC-BY 1.0).
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