scholarly journals Corrosion Characterization of Iron-Based High-Performance Amorphous-Metal Thermal-Spray Coatings

2005 ◽  
Author(s):  
J. C. Farmer ◽  
J. J. Haslam ◽  
S. D. Day ◽  
D. J. Branagan ◽  
C. A. Blue ◽  
...  
Keyword(s):  
Corrosion Resistance ◽  
Thermal Spray ◽  
High Performance ◽  
Thermal Spray Technology ◽  
Published Data ◽  
Corrosion Resistant ◽  
Spray Coatings ◽  
Nickel Based Alloy ◽  
Iron Based

New corrosion-resistant, iron-based amorphous metals have been identified from published data or developed through combinatorial synthesis, and tested to determine their relative corrosion resistance. Many of these materials can be applied as coatings with advanced thermal spray technology. Two compositions have corrosion resistance superior to wrought nickel-based Alloy C-22 (UNS # N06022) in some very aggressive environments, including concentrated calcium-chloride brines at elevated temperature. One of these compositions, SAM1651, is discussed in detail to illustrate the promise of this general class of materials.

Thermal-Spray Processing of Materials

MRS Bulletin ◽  
2000 ◽  
Vol 25 (7) ◽  
pp. 12-13 ◽  
Author(s):  
S. Sampath ◽  
R. McCune
Keyword(s):  
Thermal Spray ◽  
High Performance ◽  
Surface Engineering ◽  
Thermal Spray Technology ◽  
Extreme Environments ◽  
Surface Protection ◽  
Spray Coatings ◽  
Aerospace Applications ◽  
Thermal Barriers ◽  
Operational Envelope

The enhancement of engineering materials by surface modification has extended the operational envelope for many structures in terms of resistance to corrosion, wear, fatigue, and other forms of surface degradation and has made feasible the introduction of novel materials into high-performance applications. Surface engineering, using thermal-spray coatings, represents a pragmatic and highly costeffective means of satisfying stringent design criteria (e.g., in aerospace applications), operating under extreme environments (e.g., high temperatures, wear, and corrosion), and introducing a multiplicity of functions (e.g., thermal barriers, biomedical implants, and electronic multilayers). Thermal-spray technology as a family of processes is distinguished by its ability to deposit overlays of metals, ceramics, polymers, and composites of these materials in layers of substantial thickness (e.g., >25 µm) for engineering applications, often with equipment that can operate in the atmosphere and can be portable for use in the field. While traditional applications of thermal-spray coatings have addressed issues of surface protection, there is a growing activity in the use of the basic technology concepts for producing engineered functional surfaces and devices that offer the materials engineer a new scale of construction between thin films and macroscopic structures.

scholarly journals Advances in Corrosion-Resistant Thermal Spray Coatings for Renewable Energy Power Plants: Part II—Effect of Environment and Outlook

2019 ◽  
Vol 28 (8) ◽  
pp. 1789-1850 ◽  
Author(s):  
Esmaeil Sadeghi ◽  
Nicolaie Markocsan ◽  
Shrikant Joshi
Keyword(s):  
High Temperature ◽  
Thermal Spray ◽  
Power Plants ◽  
High Temperature Corrosion ◽  
Thermal Spray Coatings ◽  
Current Status ◽  
Comprehensive Overview ◽  
Biomass Waste ◽  
Corrosion Resistant ◽  
Spray Coatings

Abstract High-temperature corrosion of critical components such as water walls and superheater tubes in biomass/waste-fired boilers is a major challenge. A dense and defect-free thermal spray coating has been shown to be promising to achieve a high electrical/thermal efficiency in power plants. The field of thermal spraying and quality of coatings have been progressively evolving; therefore, a critical assessment of our understanding of the efficacy of coatings in increasingly aggressive operating environments of the power plants can be highly educative. The effects of composition and microstructure on high-temperature corrosion behavior of the coatings were discussed in the first part of the review. The present paper that is the second part of the review covers the emerging research field of performance assessment of thermal spray coatings in harsh corrosion-prone environments and provides a comprehensive overview of the underlying high-temperature corrosion mechanisms that lead to the damage of exposed coatings. The application of contemporary analytical methods for better understanding of the behavior of corrosion-resistant coatings is also discussed. A discussion based on an exhaustive review of the literature provides an unbiased commentary on the advanced accomplishments and some outstanding issues in the field that warrant further research. An assessment of the current status of the field, the gaps in the scientific understanding, and the research needs for the expansion of thermal spray coatings for high-temperature corrosion applications is also provided.

scholarly journals Optimization and Process Control for High Performance Thermal Spray Coatings

2000 ◽  
Author(s):  
Christian Moreau ◽  
Luc Leblanc
Keyword(s):  
Process Control ◽  
Thermal Spray ◽  
Plasma Spray ◽  
High Performance ◽  
Thermal Spray Coatings ◽  
Wear Resistant Coatings ◽  
Spray Coatings ◽  
Consistent Manner ◽  
The Stability ◽  
Sprayed Coatings

Abstract Thermal spray coatings are used to protect surfaces against exposure to severe conditions. To insure a reliable protection, not only the structure and properties of the sprayed coatings must be optimized but also one needs to develop appropriate process control techniques to produce high performance coatings in a consistent manner, day after day. This is particularly important during plasma spraying as the wear of the electrodes affects significantly the plasma characteristics and consequently the coating properties. First, in this paper, the stability of plasma spray processes is investigated by monitoring in-flight particle characteristics and plasma fluctuations. Secondly, the possibility and advantages of controlling plasma spray processes by monitoring and regulating the condition of the sprayed particles are discussed. Finally, we will see how the properties of thermal barrier coatings and wear resistant coatings can be optimized by controlling the temperature and velocity of the sprayed particles both in the plasma spray and HVOF (high velocity oxy-fuel) processes.

Corrosion Resistance of Iron-Based Amorphous Metal Coatings

2006 ◽  
Author(s):  
J. C. Farmer ◽  
J. J. Haslam ◽  
S. D. Day ◽  
T. Lian ◽  
R. Rebak ◽  
...  
Keyword(s):  
Corrosion Resistance ◽  
Thermal Spray ◽  
Spent Nuclear Fuel ◽  
Amorphous Metal ◽  
High Level Waste ◽  
Metal Coatings ◽  
Spray Coatings ◽  
Type 316L ◽  
High Level ◽  
Type 316L Stainless Steel

New amorphous-metal thermal-spray coatings have been developed recently that may provide a viable coating option for spent nuclear fuel & high-level waste repositories [Pang et al. 2002; Shinimiya et al. 2005; Ponnambalam et al. 2004; Branagan et al. 2000–2004]. Some Fe-based amorphous-metal formulations have been found to have corrosion resistance comparable to that of high-performance alloys such as Ni-based Alloy C-22 [Farmer et al. 2004–2006]. These materials rely on Cr, Mo and W for enhanced corrosion resistance, while B is added to promote glass formation and Y is added to lower the critical cooling rate (CCR). Materials discussed in this paper include yttrium-containing SAM1651 with CCR ∼ 80 K/s and yttrium-free Formula 2C with CCR ∼ 600 K/s. While nickel-based Alloy C-22 and Type 316L stainless steel lose their resistance to corrosion during thermal spraying, Fe-based SAM1651 and Formula 2C amorphous-metal coatings can be applied with thermal spray processes without any significant loss of corrosion resistance. In the future, such corrosion-resistant thermal-spray coatings may enable the development of less expensive containers for spent nuclear fuel (SNF) and high-level waste (HLW), including enhanced multipurpose containers (MPCs), protected closure welds, and shields to protect containers from drips and falling rocks. These materials are extremely hard and provide enhanced resistance to abrasion and gouges from backfill operations. For example, Type 316L stainless steel has a hardness of approximately 150 VHN, Alloy C-22 has a hardness of approximately 250 VHN, while the Fe-based amorphous metals typically have hardness values of 1100–1300 VHN. Both Formula 2C and SAM1651 have high boron content which allow them to absorb neutrons, and therefore be used for enhanced criticality control. Cost savings can also be realized through the substitution of Fe-based alloy for Ni-based materials. Applications are also envisioned in oil & gas industry.

Characterization of Thermal Spray Coatings

1999 ◽  
Vol 42 (2-3) ◽  
pp. 93-100 ◽  
Author(s):  
Brian S Schorr ◽  
Kevin J Stein ◽  
Arnold R Marder
Keyword(s):  
Thermal Spray ◽  
Thermal Spray Coatings ◽  
Spray Coatings
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