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This study aims to optimise the effect of pre-oxidation on hot corrosion behaviour of Tribaloy T-900 at 900 °C in mixed Na₂SO₄ and K₂SO₄.

Prior to hot corrosion experiment, pre-oxidation treatments were carried in ambient air at 900 °C for 1, 5 and 10 h, respectively. The hot corrosion experiments were performed in a box type furnace at 900 °C. Both surfaces of specimens were brushed with saturated salt solution of 75 wt.% Na₂SO₄ + 25 wt.% K₂SO₄. After brushing, the salt-coated specimens were placed in electric stove to ensure drying of salt. After drying, presence of 3 mg/cm² salt on specimen’s surface was ensured through weighting.

The 1-h pre-oxidation treatment prior to hot corrosion showed superior hot corrosion resistance against molten salt attack. An optimum pre-oxidation time of 1 h helped timely formation of protective Cr₂O₃ layer and inhibited the formation of less stable and porous surface oxides of Ni and Mo during hot corrosion.

Pre-oxidation effect on hot corrosion behaviour of refractory metal (such as Mo in investigated alloy) containing alloy has never been reported previously. Refractory metals oxide (e.g. MoO3) could transform the corrosion phenomena to catastrophic failure through acidic fluxing.