Corrosion behavior of SiC coated HX with MoSi2 interlayer to be utilized in iodine-sulfur cycle for hydrogen production

In this era, renewable energy technologies are suitable to meet the challenges of fossil fuel depletion and global warming. Thus, hydrogen is gaining attention as an alternative clean energy carrier that can be produced from various methods, one of them is the iodine-sulfur (I-S) cycle which is a thermochemical process. The I-S cycle requires a material that can withstand an extremely corrosive environment at high temperatures. Immersion tests were conducted on bare superalloy Hastelloy X (HX), MoSi2, and SiC-MoSi2 coated HX, deposited in physical vapor deposition (PVD) to evaluate their corrosion resistance. Bare HX exhibited a high corrosion rate of 208.1 mm yr-1 when exposed to 98 wt% sulfuric acid at 300 °C. In contrast, HX with MoSi2 coating showed a much lower corrosion rate of 23.5 mm yr-1, and HX with SiC-MoSi2 coating demonstrated the lowest corrosion rate at 6.5 mm yr-1 under the same conditions. The coated samples were analyzed via FESEM before and after corrosion testing. The FESEM images reveal the formation of coalescent particles on the surface of the coating. The elemental analysis illustrates an increased concentration of silicon and oxygen in the corroded samples. Elemental mapping of these samples show a uniform distribution of elements over the sample. These findings contribute not only to materials science understanding but also to practical applications in hydrogen production via the I-S cycle, where corrosion-resistant materials are critical.