Corrosion Resistance in Nickel-Based Alloy Coatings
Summary
Nickel-based superalloys are widely applied as protective coatings to extend the service life of components in aggressive environments, including marine, oil and gas, chemical processing and power generation. Their inherent corrosion resistance arises from a dense, adherent passive film enriched in chromium, molybdenum and nickel oxides. The microstructure of the coating—often dendritic γ-Ni with interdendritic precipitates such as Laves and carbides—governs both film stability and mechanical integrity. Deposition techniques, notably laser cladding, gas metal arc welding and direct energy deposition, influence key parameters such as dilution, residual stress and defect population. Low dilution of the substrate metal preserves alloy chemistry, while optimised thermal cycles promote fine dendritic arm spacing and minimise detrimental phases. Corrosion mechanisms are dominated by pitting, crevice attack and stress corrosion cracking, each mitigated by alloy composition, microstructural control and post-deposition treatments. Emerging trends emphasise multi-scale modelling of passive film growth, in situ monitoring of defects and tailored post-weld heat treatments to balance hardness, toughness and anti-corrosion performance.
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Corrosion Resistance in Nickel-Based Alloy Coatings publication trend
The graph below shows the total number of articles in corrosion resistance in nickel-based alloy coatings across all publications each year (not limited to Nature Index journals).
Technical terms
Passivation: Formation of a thin, protective oxide layer on an alloy surface that slows further corrosion.
Dilution ratio: Proportion of substrate metal mixed into the coating during deposition, affecting composition and performance.
Laves phase: Intermetallic compound rich in Nb and Mo that forms in interdendritic regions and can influence corrosion and mechanical properties.
Pitting corrosion: Localised attack that leads to the formation of cavities or “pits” in a passive film, often initiated at defects or inclusions.
References
- Laser-clad Inconel 625 coatings on Q245R structure steel: microstructure, wear and corrosion resistance. npj Materials Degradation (2022).
- Effect of Lateral Laser-Cladding Process on the Corrosion Performance of Inconel 625. Metals (2023).
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