The Effect of Hot Treatment on Composition and Microstructure of HVOF Iron Aluminide Coatings in Na2SO4 Molten Salts

Abstract

The paper deals with the hot corrosion performance of FeAl base intermetallic HVOF coatings in molten Na2SO4 at 850 °C in an isothermal process over the span of 45 h under static conditions. The test was validated with electron microscopy and compositional analyses in the cross-section area, as well as x-ray diffraction techniques. All the coatings were characterized by Al-depleted regions, intersplat oxidation and different stoichiometric ratios of iron aluminides. The results were discussed in relation to the formation of oxide scales on the surface after exposition to corrosive media, as well as heterogeneity and defects of the sprayed coatings. The Fe40Al (at.%) powder showed quite uniform phase distribution after spraying and preserved its integrity after corrosion test; the FeCr-25% + FeAl-TiAl-Al2O3 (wt.%) and Fe46Al-6.55Si (at.%) powders exhibited interface oxidation, with localized corrosion attacks proceeding through particle boundaries and microcrack networks with no evidence of Na and S penetration. FexAly alloys are susceptible to accelerated damage and decohesion of the coating, whereas the formation of sulfides is observed at certain points.