Corrosion resistance of MCrAlX coatings in a molten chloride for thermal storage in concentrating solar power applications

Gomez-Vidal, Judith C.

doi:10.1038/s41529-017-0012-3

Title: Corrosion resistance of MCrAlX coatings in a molten chloride for thermal storage in concentrating solar power applications

Abstract

Corrosion evaluations of Incoloy 800 H (In800H) and stainless steel AISI 310 (310SS), in bare and coated conditions, were performed in 34.42 wt% NaCl – 55.47 wt% KCl at 700 °C in a nitrogen atmosphere. This NaCl–KCl composition has a melting point of 657 °C, which makes it suitable for latent-heat thermal energy storage in concentrating solar power applications. Several nickel-based MCrAlX coatings were tested, where M = Ni and/or Co and X = Y, Ta, Hf, and/or Si. Electrochemical testing was carried out to determine corrosion rates. The bare In800H and 310SS alloys corroded rapidly (~2500 and 4500 µm/yr, respectively, assuming uniform corrosion). Concentrating solar power plants need containment materials with a lifetime of at least 30 years; thus, these corrosion rates are excessive. Corrosion mitigation approaches are being investigated to obtain degradation on the order of 20 µm/yr or lower. The lowest corrosion rate of 190 µm/yr was obtained for atmospheric plasma spray NiCoCrAlY coatings pre-oxidized in air at 900 °C for 24 h with a heating/cooling rate of 0.5 °C/min. Metallographic characterization of the corroded surfaces showed that the formation of a uniform thin alumina scale before exposure to the molten chloride system considerably reduced the corrosionmore »« less

Authors:

^[1]

National Renewable Energy Lab. (NREL), Golden, CO (United States)

Publication Date:: Mon Sep 18 00:00:00 EDT 2017

Research Org.:: National Renewable Energy Laboratory (NREL), Golden, CO (United States)

Sponsoring Org.:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Renewable Power Office. Solar Energy Technologies Office

OSTI Identifier:: 1394112

Report Number(s):: NREL/JA-5500-68444
Journal ID: ISSN 2397-2106

Grant/Contract Number:: AC36-08GO28308

Resource Type:: Accepted Manuscript

Journal Name:: npj Materials Degradation

Additional Journal Information:: Journal Volume: 1; Journal Issue: 7; Journal ID: ISSN 2397-2106

Publisher:: Springer

Country of Publication:: United States

Language:: English

Subject:: 14 SOLAR ENERGY; 47 OTHER INSTRUMENTATION; molten salts; corrosion; chlorides; coatings; alumina; oxidation

Citation Formats


                    Gomez-Vidal, Judith C. Corrosion resistance of MCrAlX coatings in a molten chloride for thermal storage in concentrating solar power applications.  United States: N. p., 2017. 
Web.  doi:10.1038/s41529-017-0012-3.

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                    Gomez-Vidal, Judith C. Corrosion resistance of MCrAlX coatings in a molten chloride for thermal storage in concentrating solar power applications.  United States.  https://doi.org/10.1038/s41529-017-0012-3

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                    Gomez-Vidal, Judith C. Mon .  
"Corrosion resistance of MCrAlX coatings in a molten chloride for thermal storage in concentrating solar power applications".  United States.  https://doi.org/10.1038/s41529-017-0012-3.  https://www.osti.gov/servlets/purl/1394112.

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@article{osti_1394112,

  title        = {Corrosion resistance of MCrAlX coatings in a molten chloride for thermal storage in concentrating solar power applications},

  author       = {Gomez-Vidal, Judith C.},

  abstractNote = {Corrosion evaluations of Incoloy 800 H (In800H) and stainless steel AISI 310 (310SS), in bare and coated conditions, were performed in 34.42 wt% NaCl – 55.47 wt% KCl at 700 °C in a nitrogen atmosphere. This NaCl–KCl composition has a melting point of 657 °C, which makes it suitable for latent-heat thermal energy storage in concentrating solar power applications. Several nickel-based MCrAlX coatings were tested, where M = Ni and/or Co and X = Y, Ta, Hf, and/or Si. Electrochemical testing was carried out to determine corrosion rates. The bare In800H and 310SS alloys corroded rapidly (~2500 and 4500 µm/yr, respectively, assuming uniform corrosion). Concentrating solar power plants need containment materials with a lifetime of at least 30 years; thus, these corrosion rates are excessive. Corrosion mitigation approaches are being investigated to obtain degradation on the order of 20 µm/yr or lower. The lowest corrosion rate of 190 µm/yr was obtained for atmospheric plasma spray NiCoCrAlY coatings pre-oxidized in air at 900 °C for 24 h with a heating/cooling rate of 0.5 °C/min. Metallographic characterization of the corroded surfaces showed that the formation of a uniform thin alumina scale before exposure to the molten chloride system considerably reduced the corrosion of the alloy. However, the rates of corrosion determined herein are considerable, highlighting the relevance of testing materials durability in solar power applications.},

  doi          = {10.1038/s41529-017-0012-3},

  journal      = {npj Materials Degradation},

  number       = 7,

  volume       = 1,

  place        = {United States},

  year         = {Mon Sep 18 00:00:00 EDT 2017},

  month        = {Mon Sep 18 00:00:00 EDT 2017}

}

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Title: Corrosion resistance of MCrAlX coatings in a molten chloride for thermal storage in concentrating solar power applications

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Citation Formats

Castable cements to prevent corrosion of metals in molten salts journal, August 2016

Behaviour and mechanisms of alkali-sulphate-induced hot corrosion on composite coatings at 900°C journal, May 2012

Hot corrosion behaviour of Fe–Al based intermetallic in molten NaVO3 salt journal, June 2009

Thermal barrier coatings for enhanced efficiency of gas turbine engines journal, December 2006

Growth kinetics and mechanisms of aluminum-oxide films formed by thermal oxidation of aluminum journal, August 2002

Corrosion resistance of alumina forming alloys against molten chlorides for energy production. II: Electrochemical impedance spectroscopy under thermal cycling conditions journal, July 2017

Materials Design for the Next Generation Thermal Barrier Coatings journal, August 2003

Hot corrosion behaviour of low Al NiCoCrAlY cladded coatings reinforced by nano-particles on a Ni-base super alloy journal, October 2010

Study of molten salt corrosion of HK-40m alloy applying linear polarization resistance and conventional weight loss techniques journal, November 2004

Some studies on hot corrosion performance of plasma sprayed coatings on a Fe-based superalloy journal, March 2005

The role of Cr in promoting protective alumina scale formation by γ-based Ti_Al_Cr alloys—I. Compatibility with alumina and oxidation behavior in oxygen journal, June 1997

Observation on the Interface of α-Al2O3/Cr2O3: Prepared by oxidation of Al45Cr7 journal, March 2013

Composition and chemical state of the ions of aluminium-oxide films formed by thermal oxidation of aluminium journal, May 2002

High-temperature oxidation and hot-corrosion behavior of a sputtered NiCrAlY coating with and without aluminizing journal, September 2006

Hot corrosion of atomized iron aluminides doped with boron and reinforced with alumina journal, February 2001

Metastable Alumina Polymorphs: Crystal Structures and Transition Sequences journal, August 1998

Wear and impact behaviour of High Velocity Air-Fuel sprayed Fe–Cr–Ni–B–C alloy coatings journal, March 2016

Hot corrosion of materials: Fundamental studies journal, December 1994

Microstructure of nanometer Al2O3 dispersion strengthened Ni-based high-temperature protective coatings by laser cladding journal, June 2009

Identification of hot corrosion resistant MCrAlY based bond coatings for gas turbine engine applications journal, May 2001

Oxidation behaviour of the alloy IC-6 and protective coatings journal, March 2004

Developing Corrosion Prevention Coating Solutions for the Canadian SCWR Concept journal, December 2015

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Structure and morphology of aluminium-oxide films formed by thermal oxidation of aluminium journal, October 2002

High temperature corrosion behaviour of a gradient NiCoCrAlYSi coating I: Microstructure evolution journal, May 2010

High temperature corrosion behaviour of a gradient NiCoCrAlYSi coating II: Oxidation and hot corrosion journal, July 2010

Corrosion evaluation of alloys and MCrAlX coatings in molten carbonates for thermal solar applications journal, December 2016

Smart overlay coatings — concept and practice journal, January 2002

Preparation and hot corrosion behaviour of an Al-gradient NiCoCrAlYSiB coating on a Ni-base superalloy journal, April 2009

Oxidation and hot corrosion behavior of gradient NiCoCrAlYSiB coatings deposited by a combination of arc ion plating and magnetron sputtering techniques journal, September 2006

Development of a low-expansion bond coating for Ni-base superalloys journal, January 1995

MCrAlY coating design based on oxidation–diffusion modelling. Part II: Lifing aspects journal, August 2014

Study by deflection of the oxygen pressure influence on the phase transformation in alumina thin films formed by oxidation of Fe3Al journal, October 2007

High-temperature corrosion of alumina-forming coatings for superalloys journal, December 1989

Heat transfer fluids for concentrating solar power systems – A review journal, May 2015

High-temperature oxidation and hot-corrosion behaviour of EB-PVD β-NiAlDy coatings journal, March 2011

Hot-corrosion behaviors of overlay-clad yttria-stabilized zirconia coatings in contact with vanadate–sulfate salts journal, April 2010

Corrosion of alloys in a chloride molten salt (NaCl-LiCl) for solar thermal technologies journal, December 2016

Corrosion behaviour of various model alloys with NaCl–KCl coating journal, September 2005

Corrosion of steels in contact with salt eutectics as latent heat storage materials: Influence of water and other impurities journal, January 1990

An electrochemical study of the effect of Li on the corrosion behavior of Ni3Al intermetallic alloy in molten (Li+K) carbonate journal, August 2009

Grain boundary structure and intergranular stress corrosion crack initiation in high temperature water of a thermally sensitised austenitic stainless steel, observed in situ journal, August 2014

Concentrating Solar Power Gen3 Demonstration Roadmap report, January 2017

A simple method for the inhibition of the corrosion of carbon steel by molten nitrate salt for thermal storage in concentrating solar power applications journal, October 2018

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Behaviour and mechanisms of alkali-sulphate-induced hot corrosion on composite coatings at 900°C
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journal, June 2009

Thermal barrier coatings for enhanced efficiency of gas turbine engines
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Growth kinetics and mechanisms of aluminum-oxide films formed by thermal oxidation of aluminum
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Corrosion resistance of alumina forming alloys against molten chlorides for energy production. II: Electrochemical impedance spectroscopy under thermal cycling conditions
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Hot corrosion behaviour of low Al NiCoCrAlY cladded coatings reinforced by nano-particles on a Ni-base super alloy
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Study of molten salt corrosion of HK-40m alloy applying linear polarization resistance and conventional weight loss techniques
journal, November 2004

Some studies on hot corrosion performance of plasma sprayed coatings on a Fe-based superalloy
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The role of Cr in promoting protective alumina scale formation by γ-based Ti_Al_Cr alloys—I. Compatibility with alumina and oxidation behavior in oxygen
journal, June 1997

Observation on the Interface of α-Al2O3/Cr2O3: Prepared by oxidation of Al45Cr7
journal, March 2013

Composition and chemical state of the ions of aluminium-oxide films formed by thermal oxidation of aluminium
journal, May 2002

High-temperature oxidation and hot-corrosion behavior of a sputtered NiCrAlY coating with and without aluminizing
journal, September 2006

Hot corrosion of atomized iron aluminides doped with boron and reinforced with alumina
journal, February 2001

Metastable Alumina Polymorphs: Crystal Structures and Transition Sequences
journal, August 1998

Wear and impact behaviour of High Velocity Air-Fuel sprayed Fe–Cr–Ni–B–C alloy coatings
journal, March 2016

Hot corrosion of materials: Fundamental studies
journal, December 1994

Microstructure of nanometer Al2O3 dispersion strengthened Ni-based high-temperature protective coatings by laser cladding
journal, June 2009

Identification of hot corrosion resistant MCrAlY based bond coatings for gas turbine engine applications
journal, May 2001

Oxidation behaviour of the alloy IC-6 and protective coatings
journal, March 2004

Developing Corrosion Prevention Coating Solutions for the Canadian SCWR Concept
journal, December 2015

Corrosion resistance of alumina-forming alloys against molten chlorides for energy production. I: Pre-oxidation treatment and isothermal corrosion tests
journal, July 2017

Inhibition effect of metal cations to intergranular stress corrosion cracking of sensitized Type 304 stainless steel
journal, April 2005

Corrosion resistance of Hastelloys in molten metal-chloride heat-transfer fluids for concentrating solar power applications
journal, May 2014

Preparation and hot corrosion behaviour of a MCrAlY+AlSiY composite coating
journal, November 2008

Structure and morphology of aluminium-oxide films formed by thermal oxidation of aluminium
journal, October 2002

High temperature corrosion behaviour of a gradient NiCoCrAlYSi coating I: Microstructure evolution
journal, May 2010

High temperature corrosion behaviour of a gradient NiCoCrAlYSi coating II: Oxidation and hot corrosion
journal, July 2010

Corrosion evaluation of alloys and MCrAlX coatings in molten carbonates for thermal solar applications
journal, December 2016

Smart overlay coatings — concept and practice
journal, January 2002

Preparation and hot corrosion behaviour of an Al-gradient NiCoCrAlYSiB coating on a Ni-base superalloy
journal, April 2009

Oxidation and hot corrosion behavior of gradient NiCoCrAlYSiB coatings deposited by a combination of arc ion plating and magnetron sputtering techniques
journal, September 2006

Development of a low-expansion bond coating for Ni-base superalloys
journal, January 1995

MCrAlY coating design based on oxidation–diffusion modelling. Part II: Lifing aspects
journal, August 2014

Study by deflection of the oxygen pressure influence on the phase transformation in alumina thin films formed by oxidation of Fe3Al
journal, October 2007

High-temperature corrosion of alumina-forming coatings for superalloys
journal, December 1989

Heat transfer fluids for concentrating solar power systems – A review
journal, May 2015

High-temperature oxidation and hot-corrosion behaviour of EB-PVD β-NiAlDy coatings
journal, March 2011

Hot-corrosion behaviors of overlay-clad yttria-stabilized zirconia coatings in contact with vanadate–sulfate salts
journal, April 2010

Corrosion of alloys in a chloride molten salt (NaCl-LiCl) for solar thermal technologies
journal, December 2016

Corrosion behaviour of various model alloys with NaCl–KCl coating
journal, September 2005

Corrosion of steels in contact with salt eutectics as latent heat storage materials: Influence of water and other impurities
journal, January 1990

An electrochemical study of the effect of Li on the corrosion behavior of Ni3Al intermetallic alloy in molten (Li+K) carbonate
journal, August 2009

Grain boundary structure and intergranular stress corrosion crack initiation in high temperature water of a thermally sensitised austenitic stainless steel, observed in situ
journal, August 2014

Concentrating Solar Power Gen3 Demonstration Roadmap
report, January 2017

A simple method for the inhibition of the corrosion of carbon steel by molten nitrate salt for thermal storage in concentrating solar power applications
journal, October 2018

Enabling chloride salts for thermal energy storage: implications of salt purity
journal, January 2019