This study is about the investigation of metal dusting (MD) on the alloys developed for coating in the petrochemical environments. Metal dusting is a corrosion phenomenon, which occurs in different materials, e.g., nickel-based alloys, resulting in material attack at high temperatures (350-800°C), when the carbon activity is greater than one (aC>1). Alloys containing higher chromium contents can form a protective chromium oxide (Cr2O3) layer to retard MD. Protective oxide layers on the alloys form protection throughout the MD reaction period. Characterisations were undertaken on Ni-Cr and Ni-Cr-X (X = Al, Nb and Ti) alloys under heat-treated environments. Alloy compositions previously predicted using first-principle calculations were experimentally produced by a vacuum arc melting process. Before MD exposure, the alloys were annealed at 1100°C in the muffle furnace, and then water-quenched (WQ) and furnace-cooled (FC). Manufactured materials were investigated by optical microscopy (OM), scanning electron microscopy (SEM), and X-ray diffraction (XRD). The binary Ni-Cr and ternary Ni-Cr-X (Al, Nb and Ti) alloys were successfully produced using a vacuum arc melting technique. There manufactured alloys had scale layers on the surface after heat treatment. The alloys after etching showed austenitic microstructures. Cross-section SEM-EDS analysis showed that the alloys had developed chromium- and aluminium-oxide (Cr2O3 and Al2O3) layers on the surface after heat treatment. XRD revealed a complete austenite phase in all the ternary alloys. Metal dusting exposures and characterisation will be undertaken in further studies.
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Investigation of Binary and Ternary Ni-Based Alloys for High-Temperature Petrochemical Coating Applications
Published:
25 June 2026
by MDPI
in The 3rd International Online Conference on Corrosion and Materials Degradation
session Surface Treatments and Coatings for Corrosion Protection
Abstract:
Keywords: Metal dusting, Ni-Cr, As-cast, Heat treatment, Scanning Electron Microscopy, X-ray diffraction
