Study of Molten Salt Corrosion of High Velocity Oxy-Fuel Sprayed Cermet and Nickel-Based Coatings at 900 °C

Samples of Cr₃C₂-NiCr cermet and NiCrBSi coatings formed by the high velocity oxy-fuel (HVOF) process on Superni 718 superalloy have been corroded in the Na₂SO₄-V₂O₅ molten salt environment at 900 °C under cyclic conditions. The hot corrosion behavior of the coatings has been investigated by means of thermogravimetric analysis, X-ray diffraction, scanning electron microscopy/energy dispersive spectroscopy, and electron probe microanalyzer techniques. Efforts have been made to formulate the mode of corrosion attack. Both the coatings protected the substrate superalloy Superni 718 completely. While protecting the superalloy, the Cr₃C₂-NiCr cermet coating partially oxidized along the splat boundaries up to the coating substrate interface, whereas only the upper part of the coating, to about 100 μm from the surface, oxidized in the case of the NiCrBSi coating. The hot corrosion resistance of both the coatings has been attributed to the formation of protective oxides of chromium/silicon at the surface and at the splat boundaries of the coatings.