A cast iron retort used for producing carbon disulphide in the Charcoal-Sulphur process usually has a lifespan of less than one year due to high-temperature corrosion. In order to improve the lifespan, two thermal-sprayed coating systems were investigated. One was an inner coating of a Fe-Cr-Al alloy surmounted by a top coating of aluminum, and the other was a single aluminum coating. After 576 hours exposure under the operating conditions, the specimens with arc-sprayed composite coatings showed a good resistance to sulphur attack. On the other hand, the results of the specimens with a single aluminum coating were found not to be satisfactory. The coatings and the coating/substrate interface were characterized by SEM, EPMA and X-ray diffraction. The results showed the existence of a reliable bonding between the composite coatings and the substrate with formation of the intermetallic compound AlCrFe2 which was beneficial against the sulphur attack.
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