Chemistry and electrochemistry of hot corrosion of metals
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Na2SO4 is the predominant chemical reactant involved in hot corrosion induced by molten sulfate salts, due to its extraordinary stability over a wide range of temperatures and oxygen partial pressures.
“The predominant chemical reactant involved in hot corrosion has been confirmed to be sodium sulfate (Na2SO4), due to its extraordinary stability over a wide range of temperatures and oxygen partial pressures [1, 6, 19].”
From A review on molten sulfate salts induced hot corrosion (2021) · cites this paper as [19]
The molten salt layer is a pure ionic conductor that physically separates the alloys from the gas phase.
“As with the thin aqueous layer on alloys in atmospheric corrosion, this molten salt layer is a pure ionic conductor which separates the alloys from the gas phase physically [1, 19, 47].”
From A review on molten sulfate salts induced hot corrosion (2021) · cites this paper as [19]
Sulfate salts easily attach onto the surfaces of high temperature components and melt to form a thin fused salt film at elevated temperatures.
“These sulfate salts easily attach onto the surfaces of high temperature components and are melted to form a thin fused salt film at elevated temperatures.”
From A review on molten sulfate salts induced hot corrosion (2021) · cites this paper as [19]
S2O7^2- is more active than O2 and SO4^2- and is reduced to SO4^2- and SO3^-, and this half-reaction can be the main reduction reaction.
“Moreover, S2O7 2is more active than other oxygen species, i.e., O2 and SO4 2- , and is reduced to SO4 2and SO3 - . This half-reaction can be the main reduction reaction [6, 19, 75].”
From A review on molten sulfate salts induced hot corrosion (2021) · cites this paper as [19]
In an O2-SO2-SO3 environment, O2 and SO2 have poor solubility in molten salt, whereas SO3 can dissolve by forming pyrosulfate ions.
“In the O2-SO2-SO3 environment (Eq. (1)), the solubilities of both O2 and SO2 in molten salt are poor. In contrast, SO3 can dissolve in molten salt because of the formation of pyrosulfate ions through Eq. (2) [1, 19].”
From A review on molten sulfate salts induced hot corrosion (2021) · cites this paper as [19]
In an oxidizing environment without SO2 or SO3, cathodic reactions including reduction of oxygen and sulfate ions may be involved.
“In the oxidizing environment without SO2 or SO3, several cathodic reactions including the reduction of oxygen and sulfate ions might be involved as shown in Eq. (18-21) [19, 84].”
From A review on molten sulfate salts induced hot corrosion (2021) · cites this paper as [19]
Chromium is widely recognized as a beneficial element to combat the hot corrosion of various alloys.
“Chromium is widely recognized as a beneficial element to combat the hot corrosion of various alloys [2, 19].”
From A review on molten sulfate salts induced hot corrosion (2021) · cites this paper as [19]
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- Authors
- Rapp, R. A.
- Affiliations
- The Ohio State University (US)
- Corresponding author
- Rapp, Robert A
- Venue
- Materials Science and Engineering
- Publisher
- Elsevier BV
- Published
- 1987-03
- Volume
- 87
- Pages
- 319-327
- ISSN
- 0025-5416 (ISSN-L)
- OpenAlex
- W2027813190
- Cited by
- 155
- References
- 26
- Citations by year
- 2026: 9 · 2025: 8 · 2024: 6 · 2023: 8 · 2022: 6 · 2021: 12 · 2020: 5 · 2019: 9 · 2018: 6 · 2017: 3 · 2016: 4 · 2015: 2 · 2014: 7 · 2013: 7 · 2012: 1
- FWCI
- 4.35
- Type
- journal article
- Language
- en
- Open access
- closed
- Locations
- Materials Science and Engineering (publishedVersion)
- Topics
- Physical Sciences › Chemical Engineering › Fluid Flow and Transfer Processes › Molten salt chemistry and electrochemical processes
- Physical Sciences › Engineering › Aerospace Engineering › High-Temperature Coating Behaviors
- Physical Sciences › Engineering › Mechanical Engineering › Metallurgical Processes and Thermodynamics
- Keywords
- hot corrosion, oxide solubility, Pourbaix diagrams, sodium sulfate, sodium metavanadate, acid solubility, electrochemical corrosion mechanism, metal oxides, iron oxide, chromium oxide, alumina
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