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Journal of Chinese Society for Corrosion and protection  2025, Vol. 45 Issue (1): 92-102    DOI: 10.11902/1005.4537.2024.154
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Hot Corrosion Behavior of Fe-based Amorphous Coatings in Mixed Salts of Na2SO4 + K2SO4 and Na2SO4 + NaCl
ZHANG Yongkang1, ZHAI Haimin1(), LI Xuqiang1, LI Wensheng1,2
1 State Key Laboratory of Advanced Processing and Recycling of Non-ferrous Metals, Lanzhou University of Technology, Lanzhou 730050, China
2 College of Physics and Electronic Engineering, Northwest Normal University, Lanzhou 730070, China
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ZHANG Yongkang, ZHAI Haimin, LI Xuqiang, LI Wensheng. Hot Corrosion Behavior of Fe-based Amorphous Coatings in Mixed Salts of Na2SO4 + K2SO4 and Na2SO4 + NaCl. Journal of Chinese Society for Corrosion and protection, 2025, 45(1): 92-102.

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Abstract  

Waste incineration is an alternative way of heating, which can reduce the dependence on fossil fuels and carbon dioxide emissions, but the elements such as S and Cl present in the waste incineration process affect the use of boiler pipes. With the increase of temperature, the hot corrosion phenomenon is intensified, and the hot end pipe component damage is also aggravated, which may cause catastrophic accidents. Therefore, the corrosion resistant protective coating on superheater tube is an effective method to solve this problem. The Fe-based amorphous coating (AMC) has the advantages of low cost and strong corrosion resistance: Firstly, the Fe-based AMC uses Fe-based multi-metallic materials as raw materials, which has lower cost than other kinds of amorphous materials; moreover, this kind of coating has excellent anti-corrosion, wear-resistant and easy to repair. Herein, a novel Fe-based AMC were prepared on 316L stainless steel substrate by detonation spraying technology. The corrosion behavior of AMC coating/316L stainless steel covered with deposit of 2 mg/cm2 mixed salts of either K2SO4 + 50%Na2SO4 or NaCl + 50%Na2SO4 (in mass fraction) was assessed at 450 and 550 oC in air respectively. Results indicate that the coating exhibited good resistance to mixed salts corrosion superior to that of 316L stainless steel substrate. After mixed salts corrosion at 450 oC for 90 h, the coating showed slight corrosion and formation of minimal corrosion products. After corrosion at 550 oC, the coating surface became rougher with visible cracking. The corrosion impact of NaCl + 50%Na2SO4 on the coating was found to be more severe than that of K2SO4 + 50%Na2SO4. This is primarily due to the reaction of NaCl with the oxide layer on the coating surface; leading to the formation of Cl2. Cl2 can penetrate the formed oxide scale, react with the uncorroded coating, induce cracks in the oxide scale, and finally accelerate the corrosion process of the coating.
Key words:  detonation spraying      Fe-based amorphous coating      hot corrosion      oxide layer     
Received:  16 May 2024      32134.14.1005.4537.2024.154
ZTFLH:  TG174  
Fund: National Natural Science Foundation of China(52265024);Lanzhou Young Scientific and Technological Talents Innovation Project(2023-QN-92)
Corresponding Authors:  ZHAI Haimin, E-mail: hmzhai@lut.edu.cn
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ZHANG Yongkang
ZHAI Haimin
LI Xuqiang
LI Wensheng

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https://www.jcscp.org/EN/10.11902/1005.4537.2024.154     OR     https://www.jcscp.org/EN/Y2025/V45/I1/92

Fig.1  SEM surface morphology (a), cross-sectional morphology (b), XRD pattern (c) and hardness profile (d) of as-prepared Fe-based amorphous coating
Fig.2  Hot corrosion kinetics of Fe-based amorphous coating at 450 and 550 oC
SampleTemperature / oCCorrosion mediumCumulative mass gain per unit area / mg·μm-2
316L stainless steel450NaCl + 50%Na2SO45.56
450K2SO4 + 50%Na2SO44.85
550NaCl + 50%Na2SO48.24
550K2SO4 + 50%Na2SO46.83
Coating450NaCl + 50%Na2SO41.60
450K2SO4 + 50%Na2SO41.21
550NaCl + 50%Na2SO43.92
550K2SO4 + 50%Na2SO43.01
Table 1  Cumulative mass gains per unit area of 316L stainless steel and Fe-based amorphous coating after hot corrosion for 90 h
Fig.3  XRD patterns of Fe-based amorphous coating after hot corrosion in K2SO4 + 50%Na2SO4 mixed salt for 90 h at 450 and 550 oC
Fig.4  3D surface profiles of Fe-based amorphous coating after hot corrosion in K2SO4 + 50%Na2SO4 mixed salt for 90 h at 450 oC (a) and 550 oC (b)
Fig.5  Surface morphologies of the coating after hot corrosion in K2SO4 + 50%Na2SO4 for 90 h at 450 oC (a-c) and 550 oC (d-f)
PositionFeCrMoOSKCl
A50.1227.5611.849.700.650.13-
B57.359.557.6721.403.120.91-
Table 2  EDS analysis results of two different positions marked with A and B in Fig.5c
Fig.6  EDS mappings of various elements in the surface area shown in Fig.5e
Fig.7  XRD patterns of Fe-based amorphous coating after hot corrosion in NaCl + 50%Na2SO4 mixed salt for 90 h at 450 and 550 oC
Fig.8  3D surface profiles of Fe-based amorphous coating after hot corrosion in NaCl + 50%Na2SO4 mixed salt for 90 h at 450 oC (a) and 550 oC (b)
Fig.9  Surface morphologies of Fe-based amorphous coating after hot corrosion in NaCl + 50%Na2SO4 mixed salt for 90 h at 450 oC (a-c) and 550 oC (d-f)
Fig.10  EDS mappings of various elements in the surface area shown in Fig.9b
PositionFeCrMoOSKCl
C57.9522.5712.295.591.29-0.31
D72.735.16-22.05--0.06
Table 3  EDS analysis results of two different positions marked with C and D in Fig.9e
Fig.11  Cross-sectional morphologies of Fe-based amorphous coating after hot corrosion in K2SO4 + 50%Na2SO4 (a, b) and NaCl + 50%Na2SO4 (c, d) mixed salts for 90 h at 450 oC (a, c) and 550 oC (b, d)
Fig.12  XPS spectra of Fe-based amorphous coating after hot corrosion in K2SO4 + 50%Na2SO4 mixed salt for 90 h at 450 oC (a-c) and 550 oC (d-f)
Fig.13  XPS spectra of Fe-based amorphous coating after hot corrosion in NaCl + 50%Na2SO4 mixed salt for 90 h at 450 oC (a-c) and 550 oC (d-f)
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