The molten carbonate fuel cell (MCFC) wet seal area has been found to experience accelerated corrosion in the presence of molten electrolyte because of simultaneous exposure to reducing and oxidizing atmospheres. Development of protective coatings plays an important role in minimizing this corrosion. Various aluminizing processes, such as flame spraying, slurry spraying, pack cementation, and ion vapor deposition, have been evaluated for their effectiveness. Continuous interdiffusion of aluminum and substrate Fe, Ni, and Cr occurred during high-temperature corrosion tests. Among the four aluminizing methods, ion-vapor deposition (IVD) with subsequent diffusion bonding appears to provide the most protective coating in the MCFC wet seal environment.

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