Experimental and thermodynamic investigations on the chlorine-induced corrosion of HVOF thermal sprayed NiAl coatings and 304 stainless steels at 700 °C
Open accessAbstract
Alumina-forming β-NiAl coatings were deposited by high velocity oxy-fuel (HVOF) thermal spraying onto 304 stainless steels for protection against chlorine induced corrosion in a biomass-fired boiler. The corrosion test was conducted in a synthetic gas containing 500 ppm HCl with 10 wt% KCl ash deposit at 700 °C for 250 h. Severe corrosion was observed with the fast growing alumina at the coating/substrate interface initiating from sample edges. Possible corrosion mechanism was proposed: as supplied by HCl/KCl, the formation of volatile chlorine/chloride acted as a catalyst and promoted the growth of alumina at relatively lower application temperatures (<900 °C).
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Aluminium in nickel-based HVOF coatings produces a protective layer of Al2O3 against corrosion attacks in both laboratory-scale and boiler environments.
“Alloying element such as aluminium in nickel-based HVOF coatings also produces a protective layer of Al2O3 against corrosion attacks in both laboratory-scale and boiler environments [91, 104].”
From High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review (2024) · cites this paper as [104]
Cites
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Deposition and high temperature corrosion in a 10 MW straw fired boiler
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Reddy, L., Sattari, M., Davis, C. J., Shipway, P. H., Halvarsson, M., & Hussain, T. (2019) · Corrosion Science · doi:10.1016/j.corsci.2019.07.003 · Cited by 28 · see citing works
Self-citationHigh Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review
Khantisopon, K., Singh, S., Jitputti, J., Berndt, C. C., & Ang, A. S. M. (2024) · High Temperature Corrosion of Materials · doi:10.1007/s11085-024-10251-0 · Cited by 24 · see citing works
Wu, D., Liu, S., Yuan, Z., Cao, P., Wei, X., & Zhang, C. (2021) · Journal of Thermal Spray Technology · doi:10.1007/s11666-021-01248-1 · Cited by 14 · see citing works
- Authors
- Bai, M., Reddy, L., & Hussain, T.
- Affiliations
- University of Nottingham (GB)
- Corresponding author
- Hussain, Tanvir
- Venue
- Corrosion Science
- Publisher
- Elsevier BV
- Published
- 2018-05
- Volume
- 135
- Pages
- 147-157
- ISSN
- 0010-938X (ISSN-L)
- OpenAlex
- W2794035856
- Cited by
- 81
- References
- 5
- Citations by year
- 2026: 6 · 2025: 7 · 2024: 12 · 2023: 11 · 2022: 16 · 2021: 9 · 2020: 6 · 2019: 10 · 2018: 4
- FWCI
- 5.90
- Type
- journal article
- Language
- en
- Open access
- hybrid
- doi.org
- Locations
- Corrosion Science (publishedVersion, cc-by)
- Nottingham ePrints (University of Nottingham) (submittedVersion, cc-by)
- Repository@Nottingham (University of Nottingham) (submittedVersion, cc-by)
- Funders
- Engineering and Physical Sciences Research Council (EP/M01536X/1)
- Topics
- Physical Sciences › Engineering › Aerospace Engineering › High-Temperature Coating Behaviors
- Physical Sciences › Engineering › Mechanical Engineering › Surface Treatment and Coatings
- Physical Sciences › Materials Science › Materials Chemistry › Corrosion Behavior and Inhibition
- Keywords
- chlorine-induced corrosion, NiAl coatings, HVOF spraying, 304 stainless steel, alumina growth, biomass boiler, coating-substrate interface, corrosion mechanism, high-temperature corrosion, protective coatings
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