Effects of transient carbon deposition on the sodium sulfate-induced corrosion of nickel-base alloys

The role of solid carbon in accelerating the Na₂SO₄-induced corrosion of nickel-base alloys at high temperature has been investigated. Corrosion rates of salt-coated IN 738 alloy in an oxidizing atmosphere containing 0.1 pct SO₂ were much increased when the alloy was initially exposed to a low concentration of methane for a short time at 1273 K (1000°C). Crucible tests carried out with Ni-5 Al, Ni-30 Al, Ni-20Cr-15 Al and IN 738 specimens immersed in Na₂SO₄-carbon mixtures showed that corrosion of these alloys was dramatically enhanced if the carbon persisted long enough to form a Na₂S phase by reaction with the Na₂SO₄. In an oxidizing environment a graphitic carbon had a more pernicious effect on alloy corrosion resistance than a finely dispersed carbon black which burnt away more readily. Corrosion rates in air were also accelerated in the presence of carbonized crude oil residue such as might be formed as a result of incomplete fuel combustion in a gas turbine.