Hot Corrosion Studies of HVOF-Sprayed Coating on T-91 Boiler Tube Steel at Different Operating Temperatures
Source abstract
Abstract
The aim of the present work is to investigate the usefulness of high velocity oxy fuel-sprayed 75% Cr3C2-25% (Ni-20Cr) coating to control hot corrosion of T-91 boiler tube steel at different operating temperatures viz 550, 700, and 850 °C. The deposited coatings on the substrates exhibit nearly uniform, adherent and dense microstructure with porosity less than 2%. Thermogravimetry technique is used to study the high temperature hot corrosion behavior of uncoated and coated samples. The corrosion products of the coating on the substrate are analyzed by using XRD, SEM, and FE-SEM/EDAX to reveal their microstructural and compositional features for the corrosion mechanisms. It is found that the coated specimens have shown minimum weight gain at all the operating temperatures when compared with uncoated T-91 samples. Hence, coating is effective in decreasing the corrosion rate in the given molten salt environment. Oxides and spinels of nickel-chromium may be the reason for successful resistance against hot corrosion.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: High-Temperature Coating Behaviors · Advanced materials and composites · Nuclear Materials and Properties
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (45)
Show source-provided references
1. N. Eliaz, G. Shemesh, and R.M. Latanision, Hot Corrosion in Gas Turbine Components, Eng. Failure Anal., 2002, 9, p 31–4310.1016/S1350-6307(00)00035-2 ↗
2. T.S. Sidhu, A. Malik, S. Prakash, and R.D. Agrawal, Oxidation and Hot Corrosion Resistance of HVOF WC-NiCrFeSiB Coating on Ni- and Fe-Based Superalloys at 800 °C, J. Therm Spray Technol., 2007, 16, p 844–84910.1007/s11666-007-9106-8 ↗
3. W.M. Zhao, Y. Wang, L.X. Dong, K.Y. Wu, and J. Xue, Corrosion Mechanism of NiCrBSi Coatings Deposited by HVOF, Surf. Coat. Technol., 2005, 190(2-3), p 293–29810.1016/j.surfcoat.2004.04.057 ↗
4. T.S. Sidhu, S. Prakash, and R.D. Agrawal, Studies on the Properties of High-Velocity Oxy-Fuel Thermal Spray Coatings for Higher Temperature Applications, Mater. Sci., 2005, 41(6), p 805–82310.1007/s11003-006-0047-z ↗
5. G.R. Heath, P. Hiemgartner, G. Irons, R. Miller, and S. Gustafsson, An Assessment of Thermal Spray Coating Technologies for High Temperature Corrosion Protection, Mater. Sci. Forum, 1997, 251-254, p 809–81610.4028/www.scientific.net/MSF.251-254.809 ↗
6. T.S. Sidhu, S. Prakash, and R.D. Agrawal, State of the Art of HVOF Coating Investigation—A Review, Mar. Technol. Soc. J., 2005, 39(2), p 55–6610.4031/002533205787443908 ↗
7. M.A. Uusitalo, P.M.J. Vuoristo, and T.A. Mantyla, High Temperature Corrosion of Coatings and Boiler Steels in Reducing Chlorine-Containing Atmosphere, Surf. Coat. Technol., 2002, 161(2-3), p 275–28510.1016/S0257-8972(02)00472-3 ↗
8. U. Erning and M. Nestler, Proceedings of United Thermal Spray Conference (UTSC 99). Düsseldorf, 1999, p 46210.31399/asm.cp.itsc1999p0462 ↗
9. A.C. Savarimuthu, I. Megat, H.F. Taber, J.R. Shadley, E.F. Rybicki, W.A. Emery, J.D. Nuse and D.A. Somerville, Proceedings of 1st International Thermal Spray Conference (ITSC 2000), Canada, 2000, p 109510.31399/asm.cp.itsc2000p1095 ↗
10. P.L. Ko and M.F. Robertson, Wear Characteristics of Electrolytic Hard Chrome and Thermal Sprayed WC-10 Co-4 Cr Coatings Sliding Against Al-Ni-Bronze in Air at 21 °C and at −40 °C, Wear, 2002, 252, p 880–89310.1016/S0043-1648(02)00052-2 ↗
11. T. Sahraoui, N.E. Fenineche, G. Montavon, C. Coddet, Proceedings of International Thermal Spray Conference (ITSC 2004), Japan, 2004, p 48810.31399/asm.cp.itsc2004p0488 ↗
12. Y. Harada and T. Kawamura, Control of Gas Side Corrosion in Oil Fired Boiler, Mitsubishi Heavy Ind. Tech. Rev., 1980, 17, p 139
13. Y. Harada, S. Naito, T. Tsuchiya, and Y. Nakajima, Problems of Low Grade Oil Firing Boilers and Their Solutions, Mitsubishi Heavy Ind. Tech. Rev., 1981, 18(2), p 85–95
14. E. Otero, A. Pardo, J. Hernaez, and F.J. Perez, The Corrosion of Some Superalloys (At 1000 K) in Molten Eutectic Mixture 60% V2O5-40% Na2SO4: The Influence of the Oxygen and Carbon Residues, Corros. Sci, 1992, 34, p 1747–175710.1016/0010-938X(92)90006-O ↗
15. S.N. Tiwari, Investigations on Hot Corrosion of Some Fe-, Ni- and Co-Base Superalloy in Na2SO4-V2O5 Environment Under Cyclic Conditions, Ph. D. Thesis, University of Roorkee, India, 1997
16. H. Singh, B.S. Sidhu, and S. Prakash, Mechanical and Microstructural Properties of HVOF Sprayed WC-Co and Cr3C2-NiCr Coatings on the Boiler Tube Steels Using LPG as the Fuel Gas, J. Mater. Process. Technol., 2006, 171, p 77–8210.1016/j.jmatprotec.2005.06.058 ↗
17. M. Roy, A. Pauschitz, R. Polak, and F. Franek, Comparative Evaluation of Ambient Temperature Friction Behaviour of Thermal Sprayed Cr3C2-25(Ni20Cr) Coatings with Conventional and Nano-Crystalline Grains, Tribol. Int., 2006, 39, p 29–3810.1016/j.triboint.2004.11.009 ↗
18. N. Espallargas, J. Berget, J.M. Guilemany, A.V. Benedetti, and P.H. Suegama, Cr3C2-NiCr and WC-Ni Thermal Spray Coatings as Alternatives to Hard Chromium for Erosion-Corrosion Resistance, Surf. Coat Technol., 2008, 202, p 1405–141710.1016/j.surfcoat.2007.06.048 ↗
19. L. Zhao, J. Zwick, and E. Lugscheider, HVOF Spraying of Al2O3-Dispersion-Strengthened NiCr Powders, Surf. Coat. Technol., 2004, 182(1), p 72–7710.1016/S0257-8972(03)00874-0 ↗
20. W.M. Zhao, Y. Wang, L.X. Dong, K.Y. Wu, and J. Xue, Corrosion Mechanism of NiCrBSi Coatings Deposited by HVOF, Surf. Coat. Technol., 2005, 190, p 293–29810.1016/j.surfcoat.2004.04.057 ↗
21. T.S. Sidhu, S. Prakash, and R.D. Agrawal, Performance of a High Velocity Oxy-Fuel Sprayed Coatings on a Fe-Based Superalloy in Na2SO4-60%V2O5 Environment at 900 °C, Part I: Characterisation of the Coatings, J. Mater. Eng. Perform., 2006, 15(1), p 122–12910.1361/105994906X83402 ↗
22. J.K.N. Murthy, S. Bysakh, K. Gopinath, and B. Venkataraman, Microstructure Dependent Erosion in Cr3C2-20(NiCr) Coating Deposited by a Detonation Gun, Surf. Coat. Technol., 2007, 204, p 3975–398510.1016/j.surfcoat.2010.04.069 ↗
23. L. Fedrizzi, L. Valentinelli, S. Rossi, and S. Segna, Tribo Corrosion Behavior of HVOF Cermet Coatings, Corros. Sci., 2007, 49, p 2781–279910.1016/j.corsci.2007.02.003 ↗
24. L. Mingxi, H. Yizhu, and S. Guoxiong, Microstructure and Wear Resistance of Laser Clad Cobalt-Based Alloy Multi-layer Coatings, App. Surf. Sci., 2004, 230(1-4), p 201–20610.1016/j.apsusc.2004.02.030 ↗
25. B. Yin, G. Liu, H. Zhou, J. Chen, and F. Yan, Sliding Wear Behavior of HVOF Sprayed Cr3C2-NiCr/CeO2 Composite Coatings at Elevated Temperature Upto 800 °C, Tribol. Lett., 2010, 37, p 463–47510.1007/s11249-009-9540-5 ↗
26. W. Żórawski and S. Kozerski, Scuffing Resistance of Plasma and HVOF Sprayed WC12Co and Cr3C2-25(Ni20Cr) Coatings, Surf. Coat. Technol., 2008, 202, p 4453–445710.1016/j.surfcoat.2008.04.045 ↗
27. H.S. Sidhu, B.S. Sidhu, and S. Prakash, Wear Characteristics of Cr3C2-NiCr and WC-Co Coatings Deposited by LPG Fueled HVOF, Tribol. Int., 2010, 43, p 887–89010.1016/j.triboint.2009.12.016 ↗
28. T.S. Sidhu, S. Prakash, and R.D. Agrawal, Characterizations and Hot Corrosion Resistance of Cr3C2-NiCr Coating on Ni-Base Superalloys in an Aggressive Environment, J. Therm. Spray Technol., 2006, 15(4), p 811–81610.1361/105996306X147162 ↗
29. H. Singh, Gitanjaly, S. Singh, and S. Prakash, High Temperature Corrosion Behaviour of Some Fe-, Co- and Ni-Base Superalloys in the Presence of Y2O3 as Inhibitor, Appl. Surf. Sci., 2009, 255(15), p 7062–706910.1016/j.apsusc.2009.03.040 ↗
30. S. Kamal, R. Jayaganthan, S. Prakash, and S. Kumar, Hot Corrosion Behavior of Detonation Gun Sprayed Cr3C2-NiCr Coatings on Ni and Fe-Based Superalloys in Na2SO4-60%V2O5 Environment at 900 °C, J. Alloys Compd., 2008, 463(1-2), p 358–37210.1016/j.jallcom.2007.09.019 ↗
31. N. Bala, Investigations on the Hot Corrosion Behaviour of Cold Spray and HVOF Spray Coatings on T22 and SA 516 Steels, Ph.D. Thesis, Punjab Technical University, India, 2010
32. H.S. Sidhu, B.S. Sidhu, and S. Prakash, The Role of HVOF Coatings in Improving Hot Corrosion Resistance of ASTM-SA210 GrA1 Steel in the Presence of Na2SO4-V2O5 Salt Deposits, Surf. Coat. Technol., 2006, 200(18-19), p 5386–539410.1016/j.surfcoat.2005.07.008 ↗
33. S. Singh, H.S. Sidhu, and B.S. Sidhu, High Temperature Hot Corrosion Behaviour of NiCr and Cr3 C2-NiCr coatings on T91 Boiler Steel in an Aggressive Environment at 750 °C, Surf. Coat. Technol., 2012, 206, p 3839–385010.1016/j.surfcoat.2012.01.060 ↗
34. S.N. Tiwari and S. Prakash, Studies on the Hot Corrosion Behaviour of Some Superalloys in Na2SO4-V2O5, Proc. of SOLCEC, Kalpakkam, India, 22-24th Jan., 1997, Paper C33
35. A. Ul-Hamid, Diverse Scaling Behavior of the Ni-20Cr Alloy, Mater. Chem. Phys., 2003, 80, p 135–14210.1016/S0254-0584(02)00448-0 ↗
36. H. Singh, D. Puri, and S. Prakash, Some Studies on Hot Corrosion Performance of Plasma Sprayed Coatings on a Fe-Based Superalloy, Surf. Coat. Technol., 2005, 192(1), p 27–3810.1016/j.surfcoat.2004.03.030 ↗
37. K. Sachs, Accelerated High Temperature Oxidation Due to Vanadium Pentoxide, Metallurgia, Apr., 1958, p 167-173
38. T.S. Sidhu, S. Prakash, and R.D. Agrawal, Studies of the Metallurgical and Mechanical Properties of High Velocity Oxy-Fuel Sprayed Stellite-6 Coatings on Ni- and Fe-Based Superalloys, Surf. Coat. Technol., 2006, 201, p 273–28110.1016/j.surfcoat.2005.11.108 ↗
39. R.A. Mahesh, R. Jayaganthan, and S. Prakash, Microstructural Characterization and Hardness Evaluation of HVOF Sprayed Ni-5Al Coatings on Ni- and Fe-Based Superalloys, J. Mater. Process. Technol., 2009, 209, p 3501–351010.1016/j.jmatprotec.2008.08.009 ↗
40. N. Bala, H. Singh, and S. Prakash, High Temperature Corrosion Behavior of Cold Spray Ni-20Cr Coating on Boiler Steel in Molten Salt Environment at 900 °C, J. Therm. Spray Technol., 2009, 19, p 110–11810.1007/s11666-009-9437-8 ↗
41. D. Das, R. Balasubramaniam, and M.N. Mungole, Hot Corrosion of Fe3Al, J. Mater. Sci., 2002, 37(6), p 1135–114210.1023/A:1014307219963 ↗
42. M. Kaur, H. Singh, and S. Prakash, High Temperature Corrosion Studies of HVOF Sprayed Cr3C2-NiCr Coating on SAE-347H Boiler Steel, J. Therm. Spray Technol., 2009, 18(4), p 619–63210.1007/s11666-009-9371-9 ↗
43. M. Seiersten and P. Kofstad, The Effect of SO3 on Vanadate-Induced Hot Corrosion, High Temp. Technol., 1987, 5(3), p 115–12210.1080/02619180.1987.11753353 ↗
44. M.F. Stroosnijder, R. Mevrel, and M.J. Bennet, The Interaction of Surface Engineering and High Temperature Corrosion Protection, Mater. High Temp., 1994, 12(1), p 53–6610.1080/09603409.1994.11689470 ↗
45. T.S. Sidhu, S. Prakash, and R.D. Agrawal, Hot Corrosion Studies of HVOF Sprayed Cr3C2-NiCr and Ni-20Cr Coatings on a Nickel Based Superalloy at 900 °C, Surf. Coat. Technol., 2006, 201, p 792–80010.1016/j.surfcoat.2005.12.030 ↗