Hostname: page-component-586b7cd67f-dlnhk Total loading time: 0 Render date: 2024-11-23T04:45:55.134Z Has data issue: false hasContentIssue false
  • English
  • Français

Hot corrosion behavior of thermal spray coatings on superalloy in coal-fired boiler environment

Published online by Cambridge University Press:  29 September 2015

Subhash Kamal ,
Korada Viswanatha Sharma ,
Rengaswamy Jayaganthan  and
Satya Prakash
Subhash Kamal*
Affiliation:
Department of Petroleum Engineering, Universiti Teknologi PETRONAS, Bander Seri Iskander, Tronoh 32610, Malaysia
Korada Viswanatha Sharma
Affiliation:
Department of Mechanical Engineering, Universiti Teknologi PETRONAS, Bander Seri Iskander, Tronoh 32610, Malaysia
Rengaswamy Jayaganthan
Affiliation:
Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, Roorkee, Uttarakhand 247667, India
Satya Prakash
Affiliation:
Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, Roorkee, Uttarakhand 247667, India
*
a)Address all correspondence to this author. e-mail: [email protected]
Get access

Abstract

Coal is an attractive fuel owing to its low price linked to its worldwide availability but combustion of coal generates very corrosive media especially near the superheater tubes. The present investigation is an attempt to evaluate the hot corrosion behavior of detonation-gun sprayed coatings of Cr3C2–NiCr, NiCrAlY + 0.4 wt% CeO2, and NiCoCrAlYTa on superfer 800H, exposed to low temperature super-heater zone of the coal-fired boiler. The specimens were hanged in the platen super-heater of coal-fired boiler where the gas temperature was around 900 °C ± 10 °C. Hot corrosion experiments were performed for 10 cycles, each cycle consisting of 100 h exposure followed by 1 h cooling at ambient temperature. All three coatings deposited on superfer 800H imparted better hot corrosion resistance than the bare uncoated one. The Cr3C2–NiCr coated superalloy performed better than the other two coatings in the given boiler environment.

Keywords

hot corrosionsuperfer 800Hboiler environmentcoatingsdetonation-gun
Type
Articles
Information
Journal of Materials Research , Volume 30 , Issue 18 , 28 September 2015 , pp. 2829 - 2843
Copyright
Copyright © Materials Research Society 2015 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

REFERENCES

Sidhu, T.S., Prakash, S., and Agrawal, R.D.: Hot corrosion studies of HVOF NiCrBSi and Stellite-6 coatings on a Ni-based superalloy in an actual industrial environment of a coal fired boiler. Surf. Coat. Technol. 201(3–4), 1602 (2006).CrossRefGoogle Scholar
Bala, N., Singh, H., and Prakash, S.: Accelerated hot corrosion studies of cold spray Ni–50Cr coating on boiler steels. Mater. Des. 31, 244 (2010).Google Scholar
Levy, A.V.: The erosion-corrosion of tubing steels in combustion boiler environments. Corros. Sci. 35(5–8), 1035 (1993).Google Scholar
Zheng, L., Maicang, Z., and Jianxin, D.: Hot corrosion behavior of powder metallurgy Rene 95 nickel-based superalloy in molten NaCl Na2SO4 salts. Mater. Des. 32(4), 1981 (2011).Google Scholar
Sidhu, B.S. and Prakash, S.: Degradation behavior of Ni3Al plasma-sprayed boiler tube steels in an energy generation system. J. Mater. Eng. Perform. 14(3), 356 (2005).CrossRefGoogle Scholar
Kamal, S., Jayaganthan, R., and Prakash, S.: Mechanical and microstructural characteristics of detonation gun sprayed NiCrAlY + 0.4 wt% CeO2 coatings on superalloys. Mater. Chem. Phys. 122(1), 262 (2010).Google Scholar
Kamal, S., Jayaganthan, R., and Prakash, S.: Characterisation of detonation gun sprayed Cr3C2–25% NiCr coatings on Ni- and Fe-based superalloys. Surf. Eng. 25(4), 287 (2009).Google Scholar
Kamal, S., Jayaganthan, R., and Prakash, S.: Mechanical and microstructural characterisations of NiCrCoAlYTa coatings on superalloys deposited by detonation gun technique. Surf. Eng. 25(4), 303 (2009).Google Scholar
Sidhu, B.S. and Prakash, S.: Evaluation of the behavior of shrouded plasma spray coatings in the platen superheater of coal-fired boilers. Metall. Mater. Trans. A 37, 1927 (2006).Google Scholar
Sidhu, T.S., Prakash, S., and Agrawal, R.D.: Hot corrosion performance of a NiCr coated Ni-based alloy. Scr. Mater. 55, 179 (2006).CrossRefGoogle Scholar
Srivastava, S.C., Godiwalla, K.M., and Banerjee, M.K.: Fuel ash corrosion of boiler and superheater tubes. J. Mater.Sci. 32, 835 (1997).Google Scholar
Weulersse-Mouterat, K., Moulin, G., Billard, P., and Pierotti, G.: High temperature corrosion of superheater tubes in waste incinerators and coal-fired plants. Mater. Sci. Forum 461–464, 973 (2004).Google Scholar
Bala, N., Singh, H., Prakash, S., and Karthikeyan, J.: Investigations on the behavior of HVOF and cold sprayed Ni-20Cr coating on T22 boiler steel in actual boiler environment. J. Therm. Spray Technol. 21(1), 144 (2012).Google Scholar
Kamal, S., Jayaganthan, R., and Prakash, S.: Hot corrosion studies of detonation-gun-sprayed NiCrAlY+0.4wt%CeO2 coatings on superalloys in molten salt environment. J. Mater. Eng. Perform. 20(6), 1068 (2010).Google Scholar
Sundararajan, T., Kuroda, S., Nishida, K., Itagaki, T., and Abe, F.: Behaviour of Mn and Si in the spray powders during steam oxidation of Ni–Cr thermal spray coatings. ISIJ Int. 44(1), 139 (2004).Google Scholar
Belzunce, F.J., Higuera, V., and Poveda, S.: High temperature oxidation of HFPD thermal-sprayed MCrAlY coatings. Mater. Sci. Eng., A 297(1–2), 162 (2001).Google Scholar
Niranatlumpong, P., Ponton, C.B., and Evans, H.E.: The failure of protective oxides on plasma-sprayed NiCrAlY overlay coatings. Oxid. Met. 53(3–4), 241 (2000).Google Scholar
Zhang, T., and Li, D.Y.: Effects of cerium on dry sand erosion and corrosive erosion of aluminide coating on 1030 steel. J. Mater. Sci. Lett. 19, 429 (2000).Google Scholar
Arivazhagan, N., Narayanan, S., Singh, S., Prakash, S., and Reddy, G.M.: High temperature corrosion studies on friction welded low alloy steel and stainless steel in air and molten salt environment at 650 °C. Mater. Des. 34, 459 (2012).Google Scholar
Gurrappa, I.: Hot corrosion of protective coatings. Mater. Manuf. Processes 15(5), 761 (2000).Google Scholar
Hanyi, L., Fuhui, W., and Linxian, B.: Effect of yttrium on the hot-corrosion resistance of sputtered CoCrAl coatings. Mater. Sci. Eng., A 123(1), 123 (1990).Google Scholar