Corrosion of nickel in sodium sulphate-sodium chloride melts. Part I

The corrosion behaviour of Ni in molten Na₂SO₄, NaCl, and in mixtures of these two salts, at 900° C, in laboratory air and under O₂+SO₂/SO₃ atmospheres has been examined by electrochemical curves and topochemical analysis of corrosion products.Ni passivity in pure Na₂SO₄ was observed under potentiodynamic and potentiometric conditions, the passive film corresponding to NiO. Passivity was not so easy to achieve in chloride melts as in sulphate alone, but once a thick oxide film forms on the specimen, the Cl^– addition is accompanied by an increase in the film stability. The inhibiting role of NaCl on Ni in the passive-transpassive area was also evidenced. In opposition, halide additions (especially those up to 25%) increased the dissolution current densities of Ni in the active region. These higher dissolution rates are represented by the equation Ni₃S₂+4NaCl+1/2 O₂ = 2NiCl₂+2Na₂S + NiO which is also suggested as a critical factor in the Ni passivation.The passive capability found for Ni in Na₂SO₄/NaCl melts, in air, is destroyed by SO₃ atmospheres. This corrosion-stimulation is due to the SO₃ role in promoting reactions such as NiS + 3O^2– = Ni²⁺+SO₃+8e which would be potential-determining at the Ni surface until Ni²⁺ precipitates or the conjugate oxygen cathodic reduction process takes place. Microprobe analysis also evidenced S penetration which might be the reason for the Ni embrittlement.The polarization curves for Ni in pure NaCl showed the lack of a passive region; occurrence of extensive intergranular attack was also indicated by metallographic observation. The observed dissolution must occur at the expense of the Ni interactions with the species which intervene in the reaction equilibrium between O₂ and molten NaCl (O₂, Cl^–, Cl₂ and O^2–) as well as with the Na⁺ cations, as has been discussed elsewhere. Its self-sustaining nature is enhanced by the continuous reduction of the nickel ion content of the melt by NiCl₂ evaporation.