Erosion corrosion is a major obstacle in the commercial growth of an industry. Single-phase erosion corrosion has been the primary cause of pipeline failures.

Petrochemical and nuclear plants are prone to erosion-corrosion. Erosion removes the protective metal film, exposing bare metals to corrosion.

This results in perforation of metallic components, which exponentially declines the working life of equipment.

Erosion corrosion led to the failure of feed water pipeline in the Surry-2 reactor on December 9, 1986.

The erosion process can be controlled by boronizing. It provides resistance against wear and fatigue and provides tensile strength to the material.

A few factors need to be monitored while undergoing the boronizing process:


The composition of boronizing layer is a critical factor that depends on the base material. Typically, it should include at least one or more boron oxide, boron fluoride, and a molten salt.


If the boronizing process is performed on nickel alloy, it will form Ni4B3/Ni3B/Ni2B.


Thickness of boronized layer is also dependent on the nature of base material.

If the thickness is not adjusted accordingly, it can cause the layer to erode quickly, exposing the metal to corrosion. Materials with higher composition of alloys produce thinner layers while ferrous materials develop broader layers.


An experiment-based research concluded that thickness of borided layer increased with finer boride powder. The smaller sized particles had greater adhesion, creating thicker layers.

A considerable increase was also observed in the hardness of layers. The finest size powder resulted in a boride layer with very high micro hardness.


Temperature is the factor that affects the cost and quality of boriding process.

The metal substrate is brought in contact with the boron composition and is heated typically at a temperature of 380°C while applying pressure for a minimum of one hour. The range of temperature varies with the base material. For iron, the working temperature is 650°C.

Failure to comply with the desired requirements may result in a low quality boronized material. This may cause it to deteriorate at high temperature and will offer lower resistance against erosion.

VaporKote strives to provide its customers with high quality services against erosion and corrosion. We provide exceptional boronizing and aluminizing services that allow you to operate your machinery at high temperatures.

We perform a design analysis prior to implementing it to ensure it provides the desired result along with cost-effectiveness. Contact us today to get assistance in your metallurgical processes.

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