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Effect of Iron (Fe) on the Corrosion Performance of NiCr-based Alloys
* 1, 2 , 2 , 1 , 1
1  Advanced Materials Division, Mintek, 200 Malibongwe Drive, Randburg, 2194, South Africa
2  School of Chemical and Metallurgical Engineering, University of the Witwatersrand, Braamfontein, Johannesburg, 2050, South Africa
Academic Editor: Frank Cheng

Abstract:

Critical petrochemical industry plant equipment exposed to corrosive chemicals remains susceptible to metal dusting (MD) corrosion, resulting in infrastructure degradation, significant financial losses and huge safety risks. Metal coating is one approach used to inhibit metal dusting. Firstly, this is achieved by adding elements inhibiting the catalytic activity of iron (Fe) and nickel (Ni), such as tin (Sn) or copper (Cu). Secondly, high amounts of chromium (Cr), aluminium (Al) and silicon (Si) can be added to establish a stable protective oxide scale. NiCr-based alloys are well-known multicomponent alloys with a carefully balanced composition that provide the desired properties for various industrial applications. Although these alloys can resist corrosion to a certain extent, MD can still occur under severe conditions, resulting in serious damage to a system in operation. The composition of nickel-based alloys can be tailored to specific operating conditions to improve their reliability. This stems from the fact that alloying the Ni-Cr alloy with transition elements such as molybdenum (Mo), iron and copper can improve the corrosion resistance by promoting the oxide formation process, which contributes to oxide passivity. This study is focused on investigating the effect of adding small amounts of Fe to austenitic Ni-Cr-based alloys in the process of developing a coating material that can form stable protective phases on the surface when reacting with the process environment. The current work reports the results of the initial plan of undertaking low-temperature corrosion simulation tests (electrochemical), with the aim of exposing the coating alloys to metal-dusting environments in the near future. An arc-melting furnace was used to produce the coating alloys, followed by subsequent heat treatment in a tube furnace. Phase and microstructural analyses were conducted using an X-ray diffractometer (XRD) and optical microscopy (OM), respectively. Using an electrochemical potentiostat, corrosion resistance trends at various Fe contents were established.

Keywords: Petrochemical industry, Corrosion, Metal dusting, Metallic coating, Austenitic Ni-Cr-based alloys, Microstructure
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