High temperature erosion behavior of plasma sprayed Al2O3 coating on AISI-304 stainless steel

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Gaurav Prashar ◽  
Hitesh Vasudev
Keyword(s):  
High Temperature ◽  
Aisi 304 ◽  
Content Type ◽  
X Ray ◽  
Hot Air ◽  
Air Jet ◽  
Erosion Test ◽  
Sprayed Coating ◽  
Plasma Sprayed ◽  
High Temperature Erosion

Purpose In the present study, Al2O3 coatings were deposited on stainless steel AISI-304 material by using atmospheric plasma spraying technique to combat high temperature solid particle erosion. The present aims at the performance analysis of Al2O3 coatings at high temperature conditions. Design/methodology/approach The erosion studies were carried out at a temperature of 400°C by using a hot air-jet erosion tester for 30° and 90° impingement angles. The possible erosion mechanisms were analyzed from scanning electron microscope (SEM) micrographs. Surface characterization of the powder and coatings were conducted by using an X-ray diffractometer, SEM, equipped with an energy dispersive X-ray analyzer. The porosity, surface roughness and micro-hardness of the as-sprayed coating were measured. This paper discusses outcomes of the commonly used thermal spray technology, namely, the plasma spray method to provide protection against erosion. Findings The plasma spraying method was used to successfully deposit Al2O3 coating onto the AISI 304 substrate material. Detailed microstructural and mechanical investigations were carried out to understand the structure-property correlations. Major findings were summarized as under: the erosive wear test results indicate that the plasma sprayed coating could protect the substrate at both 30° and 90° impact angles. The coating shows better resistance at an impact angle of 30° compared with 90°, which is related to the pinning and shielding effect of the alumina particle. The major erosion wear mechanisms of Al2O3 coating were micro-cutting, micro-ploughing, splat removal and detachment of Al2O3 hard particles. Originality/value In the current study, the authors have followed the standard testing method of hot air jet erosion test as per American society for testing of materials G76-02 standard and reported the erosion behavior of the eroded samples. The coating was not removed at all even after the erosion test duration i.e. 10 min. The erosion test was continued till 3 h to understand the evolution of coatings and the same has been explained in the erosion mechanism. The outcome of the present study may be used to minimize the high temperature erosion of AISI-304 substrate.

High temperature corrosion behaviour of aluminised FC 25 cast iron using pack cementation

2019 ◽  
Vol 66 (2) ◽  
pp. 236-241 ◽  
Author(s):  
Somrerk Chandra-Ambhorn ◽  
Neramit Krasaelom ◽  
Tummaporn Thublaor ◽  
Sirichai Leelachao
Keyword(s):  
Cast Iron ◽  
High Temperature ◽  
Corrosion Behaviour ◽  
Mass Gain ◽  
High Temperature Corrosion ◽  
Pack Cementation ◽  
X Ray Diffraction ◽  
Content Type ◽  
X Ray ◽  
Seat Insert

Purpose This study aims to apply the pack cementation to develop the Fe-Al layers on the surface of FC 25 cast iron in order to increase the high-temperature corrosion resistance of the alloy. Design/methodology/approach Pack cementation was applied on the surface of FC 25 cast iron at 1,050°C. The bare and aluminised alloys were subjected to the oxidation test in 20 per cent O2-N2 at 850 °C. Scanning electron microscopy equipped with energy-dispersive X-ray spectroscopy and X-ray diffraction (XRD) were used for characterisation. Findings The layers of pack cementation consisted of Fe2Al5, FeAl2 and FeAl, and solid solution alloyed with Al. The oxidation kinetics of the bare cast iron was parabolic. Mass gain of the aluminised cast iron was significantly decreased compared with that of the bare cast iron. This was because of the protective alumina formation on the aluminised alloy surface. Al in the Fe–Al layer also tended to be homogenised during oxidation. Originality/value Even though the aluminising of alloys was extensively studied, the application of that process to the FC 25 cast iron grade was originally developed in this work. The significantly reduced mass gain of the aluminised FC 25 cast iron makes the studied alloy be promising for the use as a valve seat insert in an agricultural single-cylinder four-stroke engine, which might be run by using a relatively cheaper fuel, i.e. LPG, but as a consequence requires the higher oxidation resistance of the engine parts.

Compared Study on Laser Cladding and Plasma Spraying of Nuclear Valve Clacks

2007 ◽  
Vol 353-358 ◽  
pp. 890-893
Author(s):  
Chun Liang Zhang ◽  
Li Ping Chen ◽  
Bin He
Keyword(s):  
High Temperature ◽  
Plasma Spraying ◽  
Laser Cladding ◽  
Base Alloy ◽  
Experimental Results ◽  
Temperature Impact ◽  
Electron Microscopes ◽  
Sprayed Coating ◽  
Plasma Sprayed ◽  
Scanning Electron Microscopes

Laser cladding of Co-base alloy on the sealing surfaces of nuclear valve clacks has been performed with a 5KW CO2 transverse flowing laser. The laser cladding was compared with plasma spraying. Both laser cladded and plasma sprayed zones were characterized by optical and scanning electron microscopes. The high temperature impact-slide wear resistance of laser cladded and plasma sprayed coatings were studied. The experimental results showed that compared with that of plasma sprayed coating, the laser cladded coating has higher microhardness, more uniform microstructure, smaller grain size, lower dilution rate, and fewer pores and impurities. The experimental results also showed that the weight loss of plasma sprayed coating during the high temperature impact-slide wear is two times larger than that of laser cladded coating.

Cross-sectional Specimen Preparation and Observation of a Plasma Sprayed Coating Using a Focused Ion Beam/Transmission Electron Microscopy System

2000 ◽  
Vol 6 (3) ◽  
pp. 218-223
Author(s):  
Toshie Yaguchi ◽  
Takeo Kamino ◽  
Mitsumasa Sasaki ◽  
Gerard Barbezat ◽  
Ryoichi Urao
Keyword(s):  
Focused Ion Beam ◽  
Ion Beam ◽  
Specimen Preparation ◽  
Coating Film ◽  
Cross Sectional ◽  
X Ray ◽  
Bright Contrast ◽  
Transmission Electron ◽  
Sprayed Coating ◽  
Plasma Sprayed

Abstract A focused ion beam (FIB) technique was applied to cross-sectional specimen preparation to observe an interface between a plasma sprayed coating and an aluminum (Al) substrate by transmission electron microscopy (TEM). The surface of the sprayed coating film has a roughness of several tens of microns. Sputter rates for the coating film and the substrate are greatly different. The rough surface and the difference in sputter rate cause problems in making TEM specimens with smooth side walls. The top surface of the coating film was planerized by the FIB before fabricating the TEM specimen. The interfaces were investigated by TEM and energy-dispersive X-ray (EDX) analysis. The TEM observation revealed that there is a 10 nm thick amorphous layer at the interface between the coating film and substrate. The coating film consists of two kinds of sublayers with bright and dark contrast. The bright contrast sublayers were amorphous layers with thickness of 2~10 nm. The Al/Fe X-ray intensity ratio was larger in bright contrast sublayers than that in dark contrast sublayers.

Advanced High Temperature Erosion Tunnel for Testing TBC and New Turbine Blade Materials

2016 ◽  
Author(s):  
Dongyun Shin ◽  
Awatef Hamed
Keyword(s):  
High Temperature ◽  
Erosion Resistance ◽  
Experimental Investigations ◽  
Synthetic Fuels ◽  
Erosion Rates ◽  
Different Temperatures ◽  
Tunnel Design ◽  
Plasma Sprayed ◽  
The University ◽  
High Temperature Erosion

Current elevated turbine inlet temperatures were made possible by the development of blade thermal barrier coatings (TBCs). However the effectiveness of these coatings could be compromised by erosive particles ingested into the engine with the incoming air or generated by the combustion of heavy and synthetic fuels. Reliable test facilities are essential to characterize their erosion resistance in increased test temperatures. This paper provides a detailed description of an advanced high temperature erosion tunnel capable of testing at temperature of 1370 °C (2500 °F) that has been recently constructed and installed in the University of Cincinnati Gas Turbine Erosion Lab. The paper also presents an overview of both theoretical and experimental investigations dealing with the new high temperature erosion tunnel design optimization and validation with comparisons to our legacy erosion tunnels. Results are presented for tested standard plasma sprayed 7 wt% Yttria stabilized Zirconia (7YSZ) TBC coated samples’ erosion rates at different temperatures, particle impact velocities and impingement angles.

Cross-sectional Specimen Preparation and Observation of a Plasma Sprayed Coating Using a Focused Ion Beam/Transmission Electron Microscopy System

2000 ◽  
Vol 6 (3) ◽  
pp. 218-223 ◽  
Author(s):  
Toshie Yaguchi ◽  
Takeo Kamino ◽  
Mitsumasa Sasaki ◽  
Gerard Barbezat ◽  
Ryoichi Urao
Keyword(s):  
Focused Ion Beam ◽  
Ion Beam ◽  
Specimen Preparation ◽  
Coating Film ◽  
Cross Sectional ◽  
X Ray ◽  
Bright Contrast ◽  
Transmission Electron ◽  
Sprayed Coating ◽  
Plasma Sprayed

AbstractA focused ion beam (FIB) technique was applied to cross-sectional specimen preparation to observe an interface between a plasma sprayed coating and an aluminum (Al) substrate by transmission electron microscopy (TEM). The surface of the sprayed coating film has a roughness of several tens of microns. Sputter rates for the coating film and the substrate are greatly different. The rough surface and the difference in sputter rate cause problems in making TEM specimens with smooth side walls. The top surface of the coating film was planerized by the FIB before fabricating the TEM specimen. The interfaces were investigated by TEM and energy-dispersive X-ray (EDX) analysis. The TEM observation revealed that there is a 10 nm thick amorphous layer at the interface between the coating film and substrate. The coating film consists of two kinds of sublayers with bright and dark contrast. The bright contrast sublayers were amorphous layers with thickness of 2~10 nm. The Al/Fe X-ray intensity ratio was larger in bright contrast sublayers than that in dark contrast sublayers.

High Temperature Erosion Behaviors of High V-Cr-Ni Spheroidal Carbides Cast Iron

2010 ◽  
Vol 457 ◽  
pp. 255-260 ◽  
Author(s):  
Kazumichi Shimizu ◽  
Takeshi Naruse ◽  
Yaer Xinba ◽  
Hideki Teramachi ◽  
Shinji Araya ◽  
...  
Keyword(s):  
Cast Iron ◽  
High Temperature ◽  
Stainless Steels ◽  
Material Removal ◽  
Vertical Section ◽  
Cast Steel ◽  
Air Velocity ◽  
Hot Air ◽  
Erosion Properties ◽  
High Temperature Erosion

High temperature erosion occurs in production of the inorganic fibrous insulator in plant. Austenitic and martensitic stainless steels are often used for these severe high temperature erosion conditions. The paper presents erosion properties of some stainless steels, several cast iron and cast steel using a blast type high temperature erosion furnace. The solid particle erosion behavior at high temperatures (900°C) of carbon steel of S50C, carbon tool steel of SK3, SUS403, SUS630, and High V-Cr-Ni spheroidal carbides cast iron (SCI-VCrNi) are investigated. Alumina balls entrained in a stream of hot air impact on the target materials at an air velocity of 100 m/s. the impingement angle is 90°. The influence of the test temperature and the material removal are discussed. The high temperature erosion behaviors of specimens are discussed by the eroded surface morphology and vertical section observation using SEM and optical microscopy observations.

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