Structure and Electrochemical Corrosion Characteristics of Novel Single and Multilayer Nickel Aluminide based Composites

This study investigates NiAl-based composite materials produced by spark plasma sintering with various alloying additives (Cr, Co, Ti, Mo, V, Re, and Zr) and architectures (single-, two-, and three-layer configurations). The materials comprise an FCC solid solution matrix and regions with a mixed FCC–BCC structure containing large NiAl phase B2 intermetallic particles. The materials also contain the TCP phases of the Cr-Mo system ( and phases). Electrochemical and corrosion studies were conducted in an aqueous solution (25 g/L CsCl + 11 g/L KCl + 9 g/L NaCl). The multilayer material NiAl-NiCrCoMoVReTiZr/NiCrCo/NiAlCoCrMoReTiZr exhibited the most favorable characteristics in terms of the ratio of current density in the passive state and the extent of the passive state region, namely, 299 mV and 0.0014 mA/cm². The most extended region of the passive state was found for the single-layer material NiAl-NiCrCoMoVReTiZr. However, its current densities in the passive state were higher (0.0033 mA/cm²) versus 0.0013-0.0015 mA/cm² for other alloys. The lowest current density in the passive state was obtained for the NiAl-CrMoCoV material. Corrosion tests over a 6-month period revealed no mass changes or pitting traces in the material structure. This may be attributed to the chemical composition of the NiAl-based alloys, the presence of high-entropy regions, and the formation of intermetallic compounds, all of which enhance corrosion resistance.

Composite material; Corrosion studies; Multilayer material; NiAl; Spark plasma sintering

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