Arc-sprayed Coatings for High Temperature Reactors in Titanium Sponge Process

Abstract An arc-sprayed composite coating consisted of an under coat Fe25Cr5Al and a top coat Al5Si was sprayed on the reactor wall surface, which is made of mild steel and used for batch production of titanium sponges. After a trial for 15 production cycles, the morphology of the sprayed coating changed greatly into somewhat like a thermal barrier coating. A large number of composite oxides containing aluminum and chromium had been generated in situ within the protective coatings, especially close to the coating/substrate interface. The oxides generated at the interface could improve the bonding of the coating to the steel substrate together with the surface alumina on the coating surface may provide an effective and long-term protection to the steel substrate of reactor at high temperatures.