The Influence of Alloying Elements on the Hot Corrosion Behavior of Nickel-Based Superalloys

Nickel-based superalloys are extensively used in high-temperature applications because of their exceptional oxidation and corrosion resistance. However, their performance in aggressive environments containing molten salts, such as Na2SO4 and V2O5, remains a critical challenge. This study investigated the hot corrosion behavior of Inconel 718, Udimet 710, Nimonic 75, and Inconel 625, focusing on the role of the alloying elements in the corrosion layers and degradation mechanisms. The superalloys were exposed to 50/50 wt.% Na2SO4–V2O5 at 900 °C for 8, 48, and 96 h, and their corrosion resistance was evaluated through weight gain measurements, scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS). These results indicate that Mo is a key factor in accelerating degradation, with Inconel 625 exhibiting the highest weight gain owing to the formation of thermally unstable Mo-rich phases. Fe also negatively impacted the stability of the protective scale of Inconel 718, contributing to an increased corrosion rate. In contrast, Nimonic 75 exhibited the best resistance, forming more of the NiCr2O4 spinel phase through the reaction of Cr2O3 with NiO from the high Ni and Cr contents in the corrosive layers. These findings highlight the importance of alloy composition in optimizing corrosion resistance and suggest that using superalloys with lower Mo and Fe contents and higher Cr and Ni concentrations can significantly enhance the durability of superalloys in molten salt environments.