Metal Corrosion and Longevity Solutions for Diffusion Alloys

Metal Corrosion and High-Temperature Protection Solutions
Understanding High-Temperature Metal Degradation
Metal degradation at high temperatures is one of the most severe challenges faced by industrial equipment and engineered components. Unlike ambient corrosion, high-temperature attack is driven by oxidation, sulphidation, carburisation, metal dusting and hot corrosion, often in aggressive atmospheres containing combustion gases, chlorides, molten salts or process chemicals.

At Diffusion Alloys, we specialise in diffusion-based surface engineering technologies that protect metals in extreme thermal environments, extending component life and maintaining mechanical integrity under demanding operating conditions.

What Causes High-Temperature Metal Damage?
In high-temperature systems, metals are exposed to chemically reactive gases and elevated thermal energy that accelerate surface reactions. Typical degradation mechanisms include:

Oxidation scaling in air and combustion environments
Sulphidation in oil and gas and petrochemical processes
Metal dusting in carbon-rich atmospheres
Chloridation in waste-to-energy and biomass systems
Hot corrosion under molten salt deposits

These mechanisms lead to material loss, embrittlement, reduced heat transfer efficiency and ultimately catastrophic component failure. Understanding the dominant exposure environment is critical in selecting the correct protective diffusion coating.

Methods to Mitigate High-Temperature Corrosion
Diffusion Aluminising
Aluminising creates a metallurgically bonded aluminium-rich surface that forms a stable aluminium oxide barrier at high temperatures. This coating system is highly effective in environments where oxidation and hot corrosion are the primary failure mechanisms.

Typical applications include:
Heat exchangers and furnace components
Gas turbines and burner assemblies
Waste-to-energy and biomass boilers
Hydrogen production and reformer systems

Aluminised surfaces can withstand prolonged exposure to temperatures exceeding 1000°C under appropriate service conditions.

Diffusion Chromising
Chromising forms a chromium-enriched diffusion layer that significantly improves resistance to sulphidation, carburisation and metal dusting. It is particularly effective where carbon activity and sulphur-bearing gases are present.

Typical applications include:
Petrochemical reformers and crackers
Syngas and hydrogen processing equipment
Coke ovens and carbon-rich process vessels
High-temperature piping in aggressive chemical atmospheres

Chromised components maintain structural stability and surface integrity in highly reducing and carbon-laden environments.

Diffusion Boronizing
Boronizing produces an extremely hard, wear-resistant surface layer with excellent performance against abrasion, erosion and sliding wear. While not a primary oxidation barrier, it is highly valuable where mechanical wear is combined with elevated temperature.

Typical applications include:
Valves and seats in high-temperature service
Extrusion and forming tooling
Pumps and wear plates operating at temperature
Components exposed to erosive particulates

Boronized surfaces dramatically reduce material loss in combined wear and thermal environments.

Enhancing Component Lifespan in Extreme Environments
Diffusion Alloys’ coating technologies do not simply cover the surface, they become part of the substrate through controlled diffusion into the base material. This metallurgical bond provides:

Superior adhesion under thermal cycling
Long-term stability at elevated temperatures
Resistance to spalling and flaking
Consistent performance over extended service intervals

Our engineers work closely with customers to match coating systems to the exact thermal, chemical and mechanical demands of each application.

Reducing Lifetime Costs through High-Temperature Protection
Premature failure of high-temperature components leads to costly shutdowns, unplanned maintenance and lost production. By applying the correct diffusion coating, operators can:

Extend component service life
Increase inspection and maintenance intervals
Reduce replacement frequency
Improve system reliability and safety

This results in measurable reductions in lifetime operating costs and improved asset performance.

Why Choose Diffusion Alloys?
Diffusion Alloys is a specialist in high-temperature surface engineering, with decades of experience protecting components used in some of the world’s most demanding industrial environments. Our focus is on delivering:

Proven diffusion coating technologies
Application-specific engineering support
Consistent, repeatable quality
Solutions tailored to real operating conditions

We work as a technical partner to help you maximise component life, increase reliability and reduce operational risk in high-temperature systems.