Improvement in hot corrosion resistance of dissimilar alloy 825 and AISI 321 CO 2 -laser weldment by HVOF coating in agg
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Improvement in hot corrosion resistance of dissimilar alloy 825 and AISI 321 CO2-laser weldment by HVOF coating in aggressive salt environment at 900°C S.M. Muthu 1), M. Arivarasu 2), T. Hari Krishna 1), Supriyo Ganguly 3), K.V. Phani Prabhakar 4), and Saurav Mohanty 5) 1) School of Mechanical Engineering, Vellore Institute of Technology, Vellore, Tamil Nadu 632014, India 2) Center for Innovative Manufacture Research, Vellore Institute of Technology, Vellore, Tamil Nadu 632014, India 3) Welding Engineering and Laser Processing Centre, Cranfield University, Bedford, United Kingdom 4) CLPM, International Advanced Research Centre for Powder Metallurgy & New Materials (ARCI), Hyderabad, India 5) Department of Mechanical Engineering, North Carolina State University, Raleigh, USA (Received: 13 November 2019; revised: 8 February 2020; accepted: 12 February 2020)
Abstract: This study investigated the hot corrosion performance of a dissimilar weldment of Ni-based superalloy and stainless steel joined by CO2-laser welding and improved by high-velocity oxy-fuel (HVOF) coating in a Na2SO4−60wt%V2O5 environment at 900°C. A dissimilar butt joint of AISI 321 and alloy 825 was fabricated by CO2-laser welding with low heat input after obtaining the optimum welding parameters by bead-on-plate trials. The metallurgical and mechanical properties of the laser weldment were evaluated. The tensile test results indicated the occurrence of fracture in the base metal AISI 321 side. The HVOF process was employed to coat Ni−20wt%Cr on the weldment. To evaluate the surface morphology of the corrosion products formed on the uncoated and Ni−20wt%Cr-coated weldments, scanning electron microscopy (SEM) analysis was performed. Energy-dispersive spectroscopy (EDS) was used to determine the different elements present on the surface scales. The existence of oxide phases on the weldments was determined by X-ray diffraction (XRD). The cross sections of the weldments were characterized by SEM with EDS line mapping analysis. The results indicated that the Ni−20wt%Cr-coated weldment exhibited superior hot corrosion resistance due to the development of Cr2O3 and NiCr2O4 protective oxide scales. Keywords: nickel-based superalloy; dissimilar welding; weldment corrosion; high-velocity oxy-fuel coating; corrosion kinetics
1. Introduction Superalloys are classified into nickel-, cobalt-, and ironbased alloys. Because of their high-temperature properties, these kinds of materials are mostly preferred for high-temperature applications; thus, they are used in power plants, gas turbines, petrochemical plants, automobiles, aircraft, and waste heat incinerators. In addition, these materials have tremendous mechanical properties such as good yield and tensile behavior, creep strength, corrosion resistance, and erosion at elevated temperatures [1−3]. Nickel-based superalloy 825 is a Ti-stabilized nickel−iron−chromium-based alloy that is mostly used for high-temperature applications; it is used in chemical and petrochem
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