Corrosion Resistance of CVD Aluminized Coating on K444 Alloy Beneath a Thin Deposits of 95%Na2SO4 + 5%NaCl at High Temperature

doi:10.11902/1005.4537.2024.029

Journal of Chinese Society for Corrosion and protection

2025, Vol. 45

Issue (1): 127-136 DOI: 10.11902/1005.4537.2024.029

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Corrosion Resistance of CVD Aluminized Coating on K444 Alloy Beneath a Thin Deposits of 95%Na₂SO₄ + 5%NaCl at High Temperature

WANG Yue¹, GENG Shujiang¹(

), WANG Jinlong¹, WANG Fuhui¹, SUN Qingyun², WU Yong², XIA Siyao²

1 Corrosion and Protection Center, Northeastern University, Shenyang 110819, China
2 Wuhan Research Institute of Materials Protection Co., Ltd., CAM, Wuhan 430030, China

Cite this article:

WANG Yue, GENG Shujiang, WANG Jinlong, WANG Fuhui, SUN Qingyun, WU Yong, XIA Siyao. Corrosion Resistance of CVD Aluminized Coating on K444 Alloy Beneath a Thin Deposits of 95%Na₂SO₄ + 5%NaCl at High Temperature. Journal of Chinese Society for Corrosion and protection, 2025, 45(1): 127-136.

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Abstract

Aluminized coating was prepared on the surface of nickel-based superalloy K444 by chemical vapor deposition (CVD) technique. The corrosion behavior of K444 alloy without and with CVD aluminized coating beneath a thin deposits film of 95%Na₂SO₄ + 5%NaCl was studied in air at 850 and 950 ^oC. The results indicate that K444 alloy showed poor corrosion resistance after 10 h corrosion. A scale of loose mixed oxides was formed on its surface, of which the outer layer is mainly composed of Cr₂O₃ and TiO₂, and the inner layer is Al₂O₃. With the increase of temperature, the corrosion was intensified and the spallation occurred of the corrosion products scale. In contrast, a protective Al₂O₃ scale was formed on the surface of the CVD aluminized coating, which effectively improves the corrosion resistance for the K444 alloy.

Key words: nickel-based superalloy hot corrosion CVD aluminized coating

Received: 17 January 2024 32134.14.1005.4537.2024.029

ZTFLH:

TG174

Fund: National Key R&D Program of China(2020YFB2010400);Hubei Provincial Key R&D Program of China(2021BAA210)

Corresponding Authors: GENG Shujiang, E-mail: gengsj@smm.neu.edu.cn

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	WANG Yue
	GENG Shujiang
	WANG Jinlong
	WANG Fuhui
	SUN Qingyun
	WU Yong
	XIA Siyao

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https://www.jcscp.org/EN/10.11902/1005.4537.2024.029 OR https://www.jcscp.org/EN/Y2025/V45/I1/127

Fig.1 Surface morphology of CVD aluminized coating

Fig.2 SEM cross-sectional morphology with EDS elements mapping of CVD aluminized coating

Fig.3 XRD pattern of CVD aluminized coating

Fig.4 Corrosion kinetic curves of K444 alloy and CVD aluminized coatings with deposit of Na₂SO₄ + NaCl

Fig.5 Surface morphologies of K444 alloy (a, b) and CVD aluminized coating (c, d) with deposit of Na₂SO₄ + NaCl at 850 ^oC (a, c) and 950 ^oC (b, d) after 10 h corrosion

Fig.6 SEM cross-sectional morphologies with EDS elements mapping of K444 alloy (a) and CVD aluminized coating (b) with deposit of Na₂SO₄ + NaCl at 850 ^oC after 10 h corrosion

Fig.7 SEM cross-sectional morphology with EDS point analysis of K444 alloy with deposit of Na₂SO₄ + NaCl at 850 ^oC after 10 h corrosion

Fig.8 SEM cross-sectional morphologies with EDS elements mapping of K444 alloy (a) and CVD aluminized coating (b) with deposit of Na₂SO₄ + NaCl at 950 ^oC after 10 h corrosion

Fig.9 SEM cross-sectional morphology with EDS point analysis of K444 alloy with deposit of Na₂SO₄ + NaCl at 950 ^oC after 10 h corrosion

Fig.10 XRD patterns of K444 alloy (a) and CVD aluminized coating (b) with deposit of Na₂SO₄ + NaCl at 850 and 950 ^oC after 10 h corrosion

Fig.11 Simplified eutectic phase diagram of Na₂SO₄-NaCl system

Fig.12 Ellingham-Richardson diagram of oxidation reactions of metallic elements

Fig.13 Ellingham-Richardson diagram of the reactions between metallic elements and solid Na₂SO₄

Fig.14 Ellingham-Richardson diagram of the reactions between metallic elements and molten Na₂SO₄

Fig.15 Ellingham-Richardson diagram of the reactions between metallic elements and molten NaCl

Fig.16 Ellingham-Richardson diagram of the reactions between metal chloride and oxygen

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