The Development of Corrosion Resistant Coatings by HVOF Spraying

2000 ◽  
Author(s):  
D. Harvey ◽  
O. Lunder ◽  
R. Henriksen
Keyword(s):  
Corrosion Resistance ◽  
Flow Rate ◽  
Corrosion Behaviour ◽  
Deposition Efficiency ◽  
Spray Angle ◽  
Powder Size ◽  
Hvof Spraying ◽  
Coating Materials ◽  
Efficient Manner ◽  
Sprayed Coatings

Abstract Coatings have been prepared using the Diamond Jet hybrid and JP5000 high velocity oxyfuel (HVOF) systems with the objectives of improving corrosion resistance and reducing costs through increasing deposition efficiency. Models relating deposition efficiency, coating oxygen content and corrosion resistance to process parameters including fuel flow rate, oxygen flow rate and stand-off distance have been developed. A corrosion test cell has been designed and a procedure determined for studying the corrosion behaviour of large numbers of thermally sprayed coatings in an efficient manner. A significant improvement to the corrosion resistance of HVOF sprayed coatings has been achieved by spraying parameter optimisation and investigation of powder size and distribution. The project has also investigated the influence of spray angle on coating performance with a view to future onsite application. Coating materials tested and compared include nickel alloys Hastelloy C276 and 59, cobalt alloy Ultimet, duplex stainless steel S32750 and an experimental iron-based spray-fuse composition.

Assessment OF HVOF Coatings for Wet Corrosion Protection

1998 ◽  
Author(s):  
M. Dvorak ◽  
P. Heimgartner
Keyword(s):  
Corrosion Protection ◽  
Corrosion Behaviour ◽  
Metallic Coatings ◽  
Hvof Spraying ◽  
Special Cases ◽  
Recent Developments ◽  
High Investment ◽  
New Generation ◽  
Thermally Sprayed ◽  
Sprayed Coatings

Abstract Until now the use of thermal sprayed metallic coatings for wet corrosion protection is limited to applications where the coating (Al-alloys, Zn-alloys and their mixtures) acts as an anode to protect the substrate or special cases, where thick cold sprayed metallic layers give good results. Other atmospheric cold sprayed layers made of corrosion resistant Ni, Co, Cu or Fe base alloys have their limitations due to the process related discontinuities like pores and oxide films. In more aggressive environments thermal sprayed and fused layers made of so called self-fluxing Ni and Co based alloys are commonly applied. Also in some applications the use of specially designed gas shrouds or of spraying techniques running in inert gas atmospheres or vacuum can yield protective coating solutions. However, these techniques have high investment or service costs or the size of the parts to be coated is restricted. Recent developments in HVOF-spraying open new possibilities in applying cold sprayed coatings on site with good corrosion resistance. The aim of this paper is on one hand to give a comparative overview about the wet corrosion behaviour of thermally sprayed metallic coatings using different spraying techniques related to the performance of the corresponding bulk materials and on the other hand to demonstrate the potential of a new generation of coatings to protect or repair structures exposed to aggressive environments.

Corrosion Behaviour of HVOF Sprayed Coatings on ASME SA213 T22 Boiler Steel in an Actual Boiler Environment

2017 ◽  
Vol 20 ◽  
pp. 1-9 ◽  
Author(s):  
Varinder Pal Singh Sidhu ◽  
Khushdeep Goyal ◽  
Rakesh Goyal
Keyword(s):  
Corrosion Behaviour ◽  
Ambient Conditions ◽  
X Ray Diffraction ◽  
Hvof Spraying ◽  
Boiler Steel ◽  
Nickel Chromium ◽  
Boiler Environment ◽  
Sprayed Coatings ◽  
Spraying Process ◽  
Thin Band

In present study HVOF spraying process had been employed for depositing 93(WC-Cr3C2)-7Ni, 75Cr3C2-25NiCr, 83WC-17CO and 86WC-10CO-4Cr coatings on ASME SA213 T22. All the coatings were found dense and uniform having thickness between 200-250µm. All the coatings on ASME SA213 T22 used in present studies have provided resistance to corrosion in coal fired boiler environment in superheater zone when exposed for 10 cycles at 900°C. Each cycle consists of 100 hours heating followed by 1 hour cooling at ambient conditions. X-ray diffraction (XRD), Scanning Electron Microscopy/Energy Dispersive Spectroscopy (SEM/EDS) techniques were used to analyse corrosion products. The results showed that among coated specimens 93(WC-Cr3C2)-7Ni and 75Cr3C2-25NiCr coatings has shown maximum and minimum resistance to corrosion respectively. The better corrosion resistance of 93(WC-Cr3C2)-7Ni coated steel alloys may be attributed to the formation of thin band of oxides of nickel, chromium; and carbides of tungsten.

Role of Aluminium on the Microstructure and Corrosion Behaviour of Magnesium Prepared by Powder Metallurgy Method

2020 ◽  
Vol 17 (3) ◽  
pp. 8206-8213
Author(s):  
J. Alias
Keyword(s):  
Corrosion Resistance ◽  
Powder Metallurgy ◽  
Corrosion Behaviour ◽  
Corrosion Current ◽  
Optical Microscope ◽  
High Reactivity ◽  
Aluminium Content ◽  
Powder Metallurgy Method ◽  
X Ray Diffraction ◽  
Promising Development

Much research on magnesium (Mg) emphasises creating good corrosion resistance of magnesium, due to its high reactivity in most environments. In this study, powder metallurgy (PM) technique is used to produce Mg samples with a variation of aluminium (Al) composition. The effect of aluminium composition on the microstructure development, including the phase analysis was characterised by optical microscope (OM), scanning electron microscopy (SEM) and x-ray diffraction (XRD). The mechanical property of Mg sample was performed through Vickers microhardness. The results showed that the addition of aluminium in the synthesised Mg sample formed distribution of Al-rich phases of Mg17Al12, with 50 wt.% of aluminium content in the Mg sample exhibited larger fraction and distribution of Al-rich phases as compared to the 20 wt.% and 10 wt.% of aluminium content. The microhardness values were also increased at 20 wt.% and 50 wt.% of aluminium content, comparable to the standard microhardness value of the annealed Mg. A similar trend in corrosion resistance of the Mg immersed in 3.5 wt.% NaCl solution was observed. The corrosion behaviour was evaluated based on potentiodynamic polarisation behaviour. The corrosion current density, icorr, is observed to decrease with the increase of Al composition in the Mg sample, corresponding to the increase in corrosion resistance due to the formation of aluminium oxide layer on the Al-rich surface that acted as the corrosion barrier. Overall, the inclusion of aluminium in this study demonstrates the promising development of high corrosion resistant Mg alloys.

Studies and Research on the Corrosion Behavior of Ni-Al2O3 Compound Coatings Obtained by Electrochemical Methods

2020 ◽  
Vol 43 (3) ◽  
pp. 21-25
Author(s):  
Simona BOICIUC ◽  
◽  
◽  
Keyword(s):  
Corrosion Resistance ◽  
Corrosion Behavior ◽  
Corrosion Behaviour ◽  
Composite Coatings ◽  
Point Of View ◽  
Electrochemical Methods ◽  
Dispersed Phase ◽  
Nickel Matrix ◽  
Technical Alumina ◽  
Compound Coatings

The undertaken research which is described in this paper aims at the corrosion behaviour of composite coatings in nickel matrix using as dispersed phase technical alumina with dimensions of 5 μm and their characterization from a microstructural point of view. The corrosion resistance in the saline fog of the coatings is influenced by the microstructure, the stresses developed in the layer and the roughness.

On the Influence of the Slot Orifice in Diesel Common Rail Nozzle

2018 ◽  
Vol 11 (1) ◽  
pp. 55-69 ◽  
Author(s):  
Giancarlo Chiatti ◽  
Ornella Chiavola ◽  
Fulvio Palmieri ◽  
Roberto Pompei
Keyword(s):  
Cross Section ◽  
Flow Rate ◽  
Experimental Analysis ◽  
Common Rail ◽  
Spray Angle ◽  
The Novel ◽  
Hydraulic Behavior ◽  
Reference Information ◽  
Light Duty ◽  
Set Up

Background:The paper deals with a diesel common rail nozzle in which a novel orifice layout is implemented.Objective:Its influence on the nozzle mechanical-hydraulic behavior and on the spray shape transient development is experimentally investigated.Methods:In the research, a solenoid injector for light duty diesel engines is equipped with the novel nozzle prototype and tested. The prototype layout is described, pointing out the features of the nozzle orifices, in which a Slot cross-section is adopted; the investigation is accomplished extending the hydraulic tests and the spray visualizations to a reference nozzle with standard holes. The influence of the hole layout on the mechanical-hydraulic behavior of the nozzle is assessed by experimental analysis based on the rate of injection measurement, in comparison with the reference nozzle. Once the hydraulic behavior of the novel nozzle has been characterized in terms of mass flow rate, the slot influence on the spray shape is assessed analyzing the macroscopic features such as the penetration distance and the spray angle, in non evaporative conditions. The study is carried out under transient injection conditions, for different injection pressures, up to 1400 bar.Results:The results on spray characteristics also provide reference information to set up spray models suited to take the Slot orifice into account.

PVD Coated Bipolar Plates for PEM Fuel Cells

2005 ◽  
Vol 2 (4) ◽  
pp. 290-294 ◽  
Author(s):  
Shuo-Jen Lee ◽  
Ching-Han Huang ◽  
Yu-Pang Chen ◽  
Chen-Te Hsu
Keyword(s):  
Corrosion Resistance ◽  
Fuel Cells ◽  
Fuel Cell ◽  
Physical Vapor Deposition ◽  
Corrosion Current ◽  
Pem Fuel Cells ◽  
Bipolar Plates ◽  
Coating Materials ◽  
Pvd Coating ◽  
Simulated Fuel

Aluminum was considered a good candidate material for bipolar plates of the polymer electrolyte membrane (PEM) fuel cells due to its low cost, light weight, high strength and good manufacturability. But there were problems of both chemical and electrochemical corrosions in the PEM fuel cell operating environment. The major goals of this research are to find proper physical vapor deposition (PVD) coating materials which would enhance surface properties by making significant improvements on corrosion resistance and electrical conductivity at a reasonable cost. Several coating materials had been studied to analyze their corrosion resistance improvement. The corrosion rates of all materials were tested in a simulated fuel cell environment. The linear polarization curve of electrochemical method measured by potentiostat instrument was employed to determine the corrosion current. Results of the corrosion tests indicated that all of the coating materials had good corrosion resistance and were stable in the simulated fuel cell environment. The conductivities of the coated layers were better and the resistances changed very little after the corrosion test. At last, single fuel cells were made by each PVD coating material. Fuel cell tests were conducted to determine their performance w.r.t. that was made of graphite. The results of fuel cell tests indicated that metallic bipolar plates with PVD coating could be used in PEM fuel cells.

scholarly journals Effect of Fluid Flow on the Corrosion Performance of as-Cast and Heat-Treated Nickel Aluminum Bronze Alloy (UNS C95800) in Saline Solution

2021 ◽  
Vol 2 (1) ◽  
pp. 61-77
Author(s):  
Hamid Reza Jafari ◽  
Ali Davoodi ◽  
Saman Hosseinpour
Keyword(s):  
Corrosion Resistance ◽  
Corrosion Behavior ◽  
Flow Rate ◽  
Solution Temperature ◽  
Aluminum Bronze ◽  
Nickel Aluminum ◽  
Nacl Solution ◽  
Flow Conditions ◽  
Heat Treated ◽  
Nickel Aluminum Bronze

In this work, the corrosion behavior and surface reactivity of as-cast and heat-treated nickel aluminum bronze casting alloy (UNS C95800) in 3.5 wt% NaCl solution is investigated under stagnant and flow conditions. Increasing flow rate conditions are simulated using a rotating disk electrode from 0 to 9000 revolutions per minute (rpm). Optical micrographs confirm the decrease in the phase fraction of corrosion-sensitive β phase in the microstructure of C95800 after annealing, which, in turn, enhances the corrosion resistance of the alloy. Electrochemical studies including open circuit potentiometry, potentiodynamic polarization, and electrochemical impedance spectroscopy are performed to assess the effect of flow rate and heat treatment on the corrosion of samples at 25 and 40 °C in 3.5 wt% NaCl solution. For both as-cast and heat-treated samples, increasing the flow rate (i.e., electrode rotating rate) linearly reduces the corrosion resistance, indicating that the metal dissolution rate is significantly affected by hydrodynamic flow. Increasing the solution temperature negatively impacts the corrosion behavior of the as-cast and heat-treated samples at all flow conditions.

Effect of Cr and Zr Addition on the Corrosion Behaviour of Copper in the Chloride Solution

2011 ◽  
Vol 194-196 ◽  
pp. 1253-1256
Author(s):  
Ya Ni Zhang ◽  
Mao Sheng Zheng ◽  
Jie Wu Zhu
Keyword(s):  
Corrosion Resistance ◽  
Chloride Solution ◽  
Corrosion Behaviour ◽  
Pure Copper ◽  
Base Material ◽  
Nacl Solution ◽  
Corrosion Performance ◽  
Zr Addition ◽  
Corrosion Scales ◽  
Better Than

The corrosion behavior of CuCr, CuZr and CuCrZr alloys in NaCl solution is reported in this paper. The corrosion performance has been evaluated in NaCl solution atmosphere. The results show the corrosion resistance of pure copper decrease with the addition of the alloying elements initially. However, in the later exposure stages, the corrosion resistance of CuZr and CuCrZr alloy deteriorates significantly while the corrosion resistance of CuCr alloy is slightly better than that of pure copper. In addition, the results of the electrochemical experiments indicate that the different behavior for the element Cr and Zr in the base material and corrosion scales lead to the change of the corrosion resistance.

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