Various thermal spraying approaches, such as air/atmospheric plasma spraying (APS) and high-velocity oxy-fuel (HVOF) spraying, are widely employed by plants owing to their flexibility, low costs and the high surface quality of the manufactured product. This study focuses on the corrosion behavior of a Ni superalloy coated with powder Cr3C2-25NiCr through APS and HVOF at 950 °C under air oxidation and Na2SO4 + 0.6V2O5 molten salt environments (MSE). The results show that HVOF-deposited Ni superalloys have higher hardness and bond strength than the respective APS coating. The thermo-gravimetric probe reveals that the Ni superalloys exposed to an oxidizing air environment has a minor mass gain compared to those under the MSE domain for both non-coated and coated samples, in line with the parabola curvature rate oxidizing law. The Ni superalloys show good corrosion resistance but poor oxidation resistance in APS-deposited Ni superalloys under the MSE. HVOF-coated Ni superalloys in both environments exhibit better corrosion resistance and lower mass gain than APS-coated superalloys. The excellent coating characteristics of HVOF-coated Ni superalloys lead to their better high-temperature corrosion performance than APS.
Keywords: air oxidation; alloy 80A; atmospheric plasma spraying; high-velocity oxy-fuel; hot corrosion resistance; molten salt environment.