Effect of Aluminum Content on Corrosion Behavior of Ni-Al Alloys in Dilute Sulfuric Acid Solution

doi:10.11902/1005.4537.2024.041

Journal of Chinese Society for Corrosion and protection

2024, Vol. 44

Issue (4): 1011-1021 DOI: 10.11902/1005.4537.2024.041

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Effect of Aluminum Content on Corrosion Behavior of Ni-Al Alloys in Dilute Sulfuric Acid Solution

DU Guang¹, LU Guoqiang², DENG Longhui¹, JIANG Jianing¹, CAO Xueqiang¹(

)

1. State Key Laboratory of Silicate Materials for Architectures, Wuhan University of Technology, Wuhan 430070, China
2. AECC Shenyang Liming Aero-Engine Co., Ltd., Shenyang 110043, China

Cite this article:

DU Guang, LU Guoqiang, DENG Longhui, JIANG Jianing, CAO Xueqiang. Effect of Aluminum Content on Corrosion Behavior of Ni-Al Alloys in Dilute Sulfuric Acid Solution. Journal of Chinese Society for Corrosion and protection, 2024, 44(4): 1011-1021.

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Abstract

Ni-based high-temperature alloys (NiCrAlY) are commonly used in the hot sections of aerospace engines. Hot section components such as combustion chambers, guide vanes, and turbine blades require thermal barrier coatings (TBCs) for protection. TBCs consist of an oxidation-resistant metal bond coat (BC) and a ceramic top coat (TC) that provides thermal insulation. The BC material is also NiCrAlY alloy, with Al and Cr content higher than the substrate Ni-based high-temperature alloys, leading to a 53 mV lower corrosion potential for BC compared to the substrate, therefore, resulting in galvanic couple with the BC. Herein, the influence of different Al contents in NiAl alloys on their corrosion behavior in dilute H₂SO₄, simulating the corrosive environment was studied. The result reveals that Ni₉₅Al₅ exhibits the highest corrosion potential and the lowest corrosion current density, while Ni₇₅Al₂₅ has a lower corrosion potential. The research demonstrates that a high Al content in the BC is the primary cause of corrosion in conditions of natural environment.

Key words: NiAl alloy dilute sulfuric acid electrochemical behavior corrosion product

Received: 30 January 2024 32134.14.1005.4537.2024.041

ZTFLH:

O646.6

Fund: National Natural Science Foundation of China(92060201)

Corresponding Authors: CAO Xueqiang, E-mail: xcao@whut.edu.cn

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	DU Guang
	LU Guoqiang
	DENG Longhui
	JIANG Jianing
	CAO Xueqiang

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https://www.jcscp.org/EN/10.11902/1005.4537.2024.041 OR https://www.jcscp.org/EN/Y2024/V44/I4/1011

Fig.1 SEM backscattered electron images of four alloys prepared by vacuum melting: (a, b) Ni₇₅Al₂₅, (c, d) Ni₈₅Al₁₅, (e) Ni₈₀Al₂₀, (f) Ni₉₅Al₅

Table 1 Chemical compositions of the regions marked in Fig.1

Fig.2 XRD patterns of four Ni-Al alloys prepared by vacuum melting (a) and local enlargement patterns of Fig.2a (b)

Fig.3 Potentiodynamic polarization curves of four Ni-Al alloys

Table 2 Fitting parameters of polarization curves of four Ni-Al alloys

Fig.4 Surface morphologies of four Ni-Al alloys after polarization test: (a, b) Ni₇₅Al₂₅, (c, d) Ni₈₀Al₂₀, (e, f) Ni₈₅Al₁₅, (g, h) Ni₉₅Al₅

Table 3 Chemical compositions of different points marked in Fig.4

Fig.5 Surface morphologies of four Ni-Al alloys after linear polarization resistance test for 48 h: (a, b) Ni₇₅Al₂₅, (c, d) Ni₈₀Al₂₀, (e, f) Ni₈₅Al₁₅, (g, h) Ni₉₅Al₅

Table 4 Average chemical composition of different regions in Fig.5

Fig.6 XPS spectra of four Ni-Al alloys after immersion in 1 mol/L H₂SO₄ solution for 48 h: (a) Ni 2p, (b) Al 2p, (c) O 1s, (d) S 2p

Fig.7 Nyquist (a-d) and Bode (e-h) plots of Ni₇₅Al₂₅ (a, e), Ni₈₀Al₂₀ (b, f), Ni₈₅Al₁₅ (c, g) and Ni₉₅Al₅ (d, h) after corrosion for different time

Fig.8 Equivalent circuit model used for fitting EIS of Ni₇₅Al₂₅ and Ni₈₀Al₂₀ (a), and Ni₈₅Al₁₅ and Ni₉₅Al₅ (b)

Fig.9 E_ocp (a) and I_corr (b) values of four Ni-Al alloys as a function of immersed time

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