The corrosion resistance of HVOF sprayed coatings with intermetallic phases in aggressive environments

Purpose: The cyclic corrosion behavior of coatings with intermetallic matrix ( FeAl, NiAl and FeAl-TiAl) was investigated in aggressive gases. Design/methodology/approach: The composite coatings strengthened by a fine dispersive Al2O3 and other ceramic phases were thermally sprayed by HVOF method in Jet Kote 2 system. A kinetics test was carried out by periodic method for exposure times of up to 500 hours. Mass changes of the studied coatings during the corrosion test are presented. The surfaces of the composite coatings after the corrosion test in aggressive environments were analyzed by scanning microscopy observation. Findings: All the results confirm good heat proofness of HVOF sprayed coatings with an AlFe and AlNi intermetallics. Practical implications: Owing to the properties of intermetallic phases and HVOF sprayed coatings, they are anticipated to be applied for the protection of super heater tubes in conventional boilers or in boilers burning multicomponent waste, and combusted biomass including chlorides. Originality/value: The results show that the coatings with AlFe and AlNi intermetallic phases have very good corrosion resistance and they are the best coatings from all the coatings investigated in aggressive environments.