How To Prevent Metal Corrosion in High-Temperature Conditions

High-temperature corrosion is a problem plaguing various industries including power plants, refineries, and petrochemical plants. Corrosion leads to $2.5 trillion worth of losses globally, every year, and high-temperature corrosion is one of the biggest causes.

Although most metals and alloys are susceptible to corrosion at high temperatures, the rate of corrosion, its mechanism, and corrosion products vary. High-temperature corrosion can lead to loss of material and physical properties as well as scaling.

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In the industrial environment, any metallic component exposed to high temperatures is at risk. Metal processing, power generation, aerospace, chemical processing, and waste incineration industries are the most common victims.

How High-Temperature Corrosion Occurs

How is it any different from normal corrosion? Well, it doesn’t require a liquid electrolyte to be present.  Also known as dry corrosion, metals react with the atoms of atmospheric gases instead of ions in a solution.

However, these gaseous attacks are not limited to oxygen. Carbon oxides, nitrous oxides, sulfur-bearing gases, halogens, etc., can also attack the metals.

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Furthermore, high-temperature corrosion leads to solid ash and salt deposits. These are contributing factors to the corrosive effect as well.

The cumulative corrosion of these contributing elements can lead to severe deterioration in the material and its physical properties. So how can it be prevented?

How to Prevent High-Temperature Corrosion: Aluminizing Process

Aluminizing presents a viable solution to the problem of high-temperature corrosion. It’s a process that can be implemented on steel as well as most metals used across different industries. Aluminum diffusion alloying or aluminizing inhibits the corrosion by protecting the surface.

Aluminizing is utilized commonly in steel, stainless steel, and nickel alloys that are being used in high-temperature conditions. It’s a high-temperature process that involves chemical vapor deposition.

In chemical vapor deposition, aluminum is vaporized and diffused into the surface. This forms new surface alloys that provide impeccable surface protection and corrosion resistance. Once aluminizing takes place, the alloys formed can’t be chipped.

Aluminizing and boronizing are largely used for the treatment of tubes that are used in sulfuric acid plants as well as nozzles and valves employed in high-temperature operations. Although a highly effective technique, very few metal coating companies offer this service, and VaporKote is one of them.

VaporKote is an aluminizing company that offers aluminized coating and corrosion protection services to industries all over the world. The company uses their own specialized powder blends to ensure optimal coating performance. The alloys formed on the surface contain at least 20% aluminum.

The coat depth is uniform throughout the area and VaporKote verifies the quality in their lab. You can also apply post heat treatments to achieve the desired mechanical properties.

Capable of aluminizing steel components up to 25 ft. in length, the company is one of the very few in the world that aluminizes metals. They also offer protective coatings for metal erosion.

VaporKote is an industry leader when it comes to diffusion coating treatments and metal surface enhancement processes. To ensure your metal parts remain corrosion free in high-temperature operations, contact VaporKote right away!

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