High performance coated
metal compositions resistant to
metal dusting
corrosion and methods of providing such compositions are provided by the present invention. The coated
metal compositions are represented by the structure (PQR), wherein P is an
oxide layer at the surface of (PQR), Q is a
coating metal layer interposed between P and R, and R is a
base metal. P includes
alumina,
chromia, silica,
mullite or mixtures thereof. Q includes Ni and Al, and at least one element selected from the group consisting of Cr, Si, Mn, Fe, Co, B, C, N, P, Ga, Ge, As, In, Sn, Sb, Pb, Sc, La, Y, Ce, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Ru, Rh, Ir, Pd, Pt, Cu, Ag, Au and mixtures thereof. R is selected from the group consisting of carbon steels, low
chromium steels, ferritic stainless steels, austenetic stainless steels, duplex stainless steels,
Inconel alloys, Incoloy alloys, Fe—Ni based alloys, Ni-based alloys and Co-based alloys. Advantages exhibited by the disclosed coated metal compositions include improved
metal dusting corrosion resistance at high temperatures in carbon-supersaturated environments having relatively
low oxygen partial pressures. The coated metal compositions are suitable for use in
syngas generation process equipment.