The interaction of different metal oxides such as Co 30,~, NiO, AI20 > Cr203, F%O 3 and SiO 2 with Na2SO ~ at a temperature of 1100 and 1200 K in flowing oxygen has been studied. The thermogravimetric studies for each system were carried out as a function of Na:, SO 4 in the mixture. The presence of different constituents in the reaction products were identified by X-ray diffraction analysis and the morphologies of the reaction products were characterized using metallography and scanning electron microscopy (SEMI. The formation of products was also investigated bv thermodynamic computation of free energies of the reactions and the study of relevant equilibrium phase diagrams. The soluble species in the aqueous solutions of the reaction products were determined quantitatively using atomic absorption spectrophotometry. The high temperature interaction products usually contain a 3-phase structure namely, Na20-M,O~, M20 ~ and metal sulphide and/or metal sulphate. The formation of Na20-M20 x depends upon the solid state solubility of metal oxide in the molten salt at high temperatures. Under limited solubility conditions Na 2 O-M 20 x is invariably formed, but as soon as this condition is relaxed the oxide. M20,. precipitates and forms a separate phase.

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The aluminide and CeO2 and La2O3 containing aluminide coatings on carbon steel have been prepared by a pack cementation process. The influence of CeO2 and La2O3 additions on the oxidation rates of aluminide coatings has been investigated. The performance of coatings was studied by measuring oxidation kinetics, metallography, SEM and X‐ray diffraction analysis techniques. The oxidation‐resistance of coated carbon steel is discussed on the basis of a decrease in oxidation rates as well as adherence of oxide scales. The oxidation rates of carbon steel and aluminide coatings were markedly reduced in the presence of CeO2 and La2O3 in the temperature range of 700‐900°C. The oxidation rates were significantly affected by the morphology of oxide scales. In the case where the structure of oxides scales was not seriously disrupted due to decarburisation, the oxidation rates were significantly reduced.

PurposeThe purpose of this paper is to present the results of studies on the reaction of metal oxides such as Cr2O3 and Al2O3 with Na2SO4 in flowing SO2 (g) at 1,100 and 1,200 K.Design/methodology/approachThe oxides chosen for the studies were initial scaling products during the oxidation of industrial alloys and invariably are involved in hot‐corrosion reactions in the presence of molten salts. The thermo‐gravimetric studies for the system were carried out as a function of Na2SO4 in the mixture. The different constituents in the reaction products were identified by XRD analysis and morphologies of the reaction products were discussed on the basis of optical metallography and scanning electron microscopic studies. The pH and conductivity of the aqueous solutions of reaction products were measured and an attempt made to functionalize these parameters with Na2SO4 concentration in the mixture. Quantitative estimation of the soluble metal was carried out using an atomic absorption spectrophotometer. The formation of products was investigated by thermodynamic computation of free energies of the reactions and the study of relevant phase stability diagrams.FindingsLooking at the complex nature of the reactions, it is difficult to generalize the conductance studies, as many complex species are liable to hydrolyze in the aqueous solution. However, the break in few curves at certain mole fraction of Na2SO4 indicates the presence of soluble complex species.Originality/valueThe paper provides information regarding the reaction between a pertinent oxide and Na2SO4 and proper identification of reaction products, useful for understanding the occurrence and importance of fluxing reactions and in the interpretation of hot corrosion mechanism and the development of new protective materials.

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