Oxidation resistance of uncoated & detonation -gun sprayed WC-12Co and Ni-20Cr coatings on T-22 boiler steel at 900°C

Hot corrosion is the serious problem in gas turbines, superheaters, and economizers of coal-fired boilers. It occurs due to the usage of wide range of fuels such as coal, oil, and so on at the elevated temperatures. Protective coatings on boiler steels are used under such environments. In the present investigation, Stellite-6 and Stellite-21 coatings have been deposited on boiler steel SAE 431 by detonation gun method. The hot corrosion performance of Stellite-6 and Stellite-21 coated as well as uncoated SAE 431 steel has been evaluated in aggressive environment of Na2SO4-82%Fe2(SO4)3under cyclic conditions at an elevated temperature of 900°C for total duration of 50 cycles. Thermogravimetric technique was used to approximate the kinetics of hot corrosion. Stellite-6 coating imparted better hot corrosion resistance than Stellite-21 coating in the given environment. Scanning electron microscopy was used to characterize the surface of hot corrosion products.

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Improving the hot corrosion resistance of boiler tube steels by detonation gun sprayed coatings in actual boiler of thermal power plant

Anti-Corrosion Methods and Materials ◽

10.1108/acmm-10-2018-2009 ◽

2019 ◽

Vol 66 (4) ◽

pp. 394-402

Author(s):

Vikramjit Singh ◽

Khushdeep Goyal ◽

Rakesh Goyal

Keyword(s):

Corrosion Resistance ◽

Corrosion Behavior ◽

Hot Corrosion ◽

Power Plants ◽

Thermal Power ◽

Boiler Steel ◽

Content Type ◽

Boiler Environment ◽

Detonation Gun ◽

Sprayed Coatings

Purpose This paper aims to investigate the hot corrosion behavior of Ni-Cr and Cr3C2-NiCr coatings, deposited on T11, P91 boiler steels by detonation gun spray coating (D-Gun) process to enhance high temperature corrosion resistance. Design/methodology/approach Hot corrosion studies were conducted in secondary super heater zone of boiler at 900 °C for 10 cycles on bare and D-Gun coated steel specimens. The microhardness and porosity values of as-sprayed coatings were measured before exposing the specimens in the boiler environment. Each cycle consisted 100 h of heating in the boiler environment followed by 20 min of cooling in air. The weight change measurements were performed after each cycle to establish the kinetics of corrosion using thermogravimetric technique. X-ray diffraction, SEM techniques were used to analyze the corroded specimens. Findings Uncoated boiler steel experienced higher weight loss. The Cr3C2-NiCr coating was found to be more protective than Ni-Cr coating. The phases revealed the formation of oxide scale on coated specimens, mainly consist of nickel and chromium, which are reported to be protective against the hot corrosion. Originality/value There is very limited reported literature on hot corrosion behavior of Ni-Cr and Cr3C2-NiCr coatings deposited on the T11 and P91 substrates by detonation gun (D-gun) spray technique. T11 and P91 alloy steels have been chosen for this study because these two alloys are used to manufacture boiler tubes used in Indian thermal power plants.

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Surface engineering, by detonation-gun spray coating, of 347H boiler steel to enhance its high temperature corrosion resistance

Materials at High Temperatures ◽

10.3184/096034011x12960473417949 ◽

2011 ◽

Vol 28 (1) ◽

pp. 1-11 ◽

Cited By ~ 7

Author(s):

G. Kaushal ◽

H. Singh ◽

S. Prakash

Keyword(s):

Corrosion Resistance ◽

High Temperature ◽

Surface Engineering ◽

Spray Coating ◽

High Temperature Corrosion ◽

Boiler Steel ◽

Detonation Gun

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Morphologies of Nonadherent Al2O3 and Matching Substrate Surfaces

Proceedings, annual meeting, Electron Microscopy Society of America ◽

10.1017/s042482010009587x ◽

1972 ◽

Vol 30 ◽

pp. 524-525

Author(s):

C. S. Giggins ◽

J. K. Tien ◽

B. H. Kear ◽

F. S. Pettit

Keyword(s):

Electron Microscopy ◽

Oxide Scale ◽

Oxidation Resistance ◽

Substrate Surface ◽

Morphological Features ◽

Thermally Induced ◽

Oxide Spallation ◽

Oxidation Resistant ◽

Induced Stresses ◽

Substrate Surfaces

The performance of most oxidation resistant alloys and coatings is markedly improved if the oxide scale strongly adheres to the substrate surface. Consequently, in order to develop alloys and coatings with improved oxidation resistance, it has become necessary to determine the conditions that lead to spallation of oxides from the surfaces of alloys. In what follows, the morphological features of nonadherent Al2O3, and the substrate surfaces from which the Al2O3 has spalled, are presented and related to oxide spallation.The Al2O3, scales were developed by oxidizing Fe-25Cr-4Al (w/o) and Ni-rich Ni3 (Al,Ta) alloys in air at 1200°C. These scales spalled from their substrates upon cooling as a result of thermally induced stresses. The scales and the alloy substrate surfaces were then examined by scanning and replication electron microscopy.The Al2O3, scales from the Fe-Cr-Al contained filamentary protrusions at the oxide-gas interface, Fig. 1(a). In addition, nodules of oxide have been developed such that cavities were formed between the oxide and the substrate, Fig. 1(a).

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Phase transformation and layer evolution in molybdenum disilicide-silicon carbide nanolayered coatings

Proceedings, annual meeting, Electron Microscopy Society of America ◽

10.1017/s0424820100170426 ◽

1994 ◽

Vol 52 ◽

pp. 538-539

Author(s):

H. Kung ◽

T. R. Jervis ◽

J.-P. Hirvonen ◽

M. Nastasi ◽

T. E. Mitchell ◽

...

Keyword(s):

Phase Transformation ◽

High Temperature ◽

Oxidation Resistance ◽

Elevated Temperatures ◽

Matrix Material ◽

Molybdenum Disilicide ◽

High Temperature Strength ◽

Cross Sectional ◽

Good Oxidation Resistance ◽

Structural Applications

MoSi2 is a potential matrix material for high temperature structural composites due to its high melting temperature and good oxidation resistance at elevated temperatures. The two major drawbacksfor structural applications are inadequate high temperature strength and poor low temperature ductility. The search for appropriate composite additions has been the focus of extensive investigations in recent years. The addition of SiC in a nanolayered configuration was shown to exhibit superior oxidation resistance and significant hardness increase through annealing at 500°C. One potential application of MoSi2- SiC multilayers is for high temperature coatings, where structural stability ofthe layering is of major concern. In this study, we have systematically investigated both the evolution of phases and the stability of layers by varying the heat treating conditions.Alternating layers of MoSi2 and SiC were synthesized by DC-magnetron and rf-diode sputtering respectively. Cross-sectional transmission electron microscopy (XTEM) was used to examine three distinct reactions in the specimens when exposed to different annealing conditions: crystallization and phase transformation of MoSi2, crystallization of SiC, and spheroidization of the layer structures.

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