Nickel-chromium plasma spray coatings: A way to enhance degradation resistance of boiler tube steels in boiler environment

Journal of Thermal Spray Technology

Volumn 15, Issue 1, 2006, Pages 131-140

  Sidhu, Buta Singh ^a   Prakash, S ^b  

^a GZS College of Engineering and Technology   (India)

^b INDIAN INSTITUTE OF TECHNOLOGY ROORKEE   (India)

Author keywords

Coal fired boilers; Coatings; Degradation; Ni 20Cr; Plasma spray

Indexed keywords

CARBON STEEL; CHROMIUM; COAL FIRED BOILERS; CORROSION RESISTANCE; ENERGY DISPERSIVE SPECTROSCOPY; NICKEL; POROSITY; SCANNING ELECTRON MICROSCOPY; SUBSTRATES;

BOILER TUBE STEELS; COATED STEELS; PLATEN SUPERHEATER ZONE;

PLASMA SPRAYING;

EID: 33645637484     PISSN: 10599630     EISSN: None     Source Type: Journal    
DOI: 10.1361/105996306X92695     Document Type: Review

References (34)

1. R.A. Rapp, J.H. Devan, D.L. Douglass, P.C. Nordine, F.S. Pettit, and D.P. Whittle, High Temperature Corrosion in Energy Systems, Mater. Sci. Eng., 1981, 50, p 1-17
2. S. Danyluk and J.Y. Park, Technical Note: Corrosion and Grain Boundary Penetration in Type 316 Stainless Steel Exposed to a Coal Gasification Environment, Corrosion, 1979, 35 (12), p 575-576
3. D. Wang, Corrosion Behavior of Chromized and/or Aluminized 2 1/4Cr-1Mo Steel in Medium-BTU Coal Gasifier Environments, Surf. Coat. Technol., 1988, 36, p 49-60
4. A.V. Levy, The Erosion-Corrosion of Tubing Steels in Combustion Boiler Environments, Corros. Sci., 1993, 35 (5-8), p 1035-1043
5. S. Prakash, S. Singh, B.S. Sidhu, and A. Madeshia, Tube Failures in Coal Fired Boilers, S. Ray, S. Singh, and S.K. Nath, Ed., Proc. National Seminar on Advances in Material and Processing, IIT, R.K. Printers and Publishers, Roorkee, India, 2001, p 245-253
6. N. Priyantha, P. Jayaweera, A. Sanjurjo, K. Lau, F. Lu, and K. Krist, Corrosion-Resistant Metallic Coatings for Applications in Highly Aggressive Environments, Surf. Coat. Technol., 163-64, p 31-36
7. M. Yoshiba, Effect of Hot Corrosion on the Mechanical Performances of Superalloys and Coating Systems, Corros. Sci., 1993, 35 (5-8), p 1115-1124
8. P. Fauchais, J. F. Coudert, and M. Vardelle, Transient Phenomena in Plasma Torches and in Plasma Sprayed Coating Generation, J. Phys. IV, 1997, 7, p C4-187-198
9. R.F. Bunshah, Handbook of Hard Coatings, Deposition Technologies, Properties and Applications, Noyes Pub., Park Ridge, NJ, 2001
10. M.D. Modi, S.C. Modi, and M.M. Mayuram, A Case Study on the Use of Plasma Sprayed Oxide Ceramic Coatings in Hot Extrusion Dies for Non-Ferrous Metals, Proc. 11th Int. Thermal Spraying Conf., September 8-12, Montreal, Canada, 1986, p 359-366
11. C. Wu and M. Okuyama, Evaluation of High Temperature Corrosion Resistance of Al Plasma Spray Coatings in Molten Sulfates at 1073 K by Electrochemical Measurements, Mater. Trans., JIM, 1996, 37 (5), p 991-997
12. V.H. Hidalgo, F.J.B. Varela, and E.F. Rico, Erosion Wear and Mechanical Properties of Plasma-Sprayed Nickel- and Iron-Based Coatings Subjected to Service Conditions in Boilers, Trib. Int., 1997, 30 (9), p 641-649
13. 2-NiCr Plasma Sprayed Coatings, Proc. of the United Thermal Spray Conf., Germany, 1999, p 683-686
14. V.H. Hidalgo, J.B. Varela, J.M. Calle, and A.C. Menendez, Characterisation of NiCr Flame and Plasma Sprayed Coatings for Use in High Temperature Regions of Boilers, Surf. Eng., 2000, 16 (2), p 137-142
15. 3Al Coatings on Steel in Oxidation and Molten Salt Environment at 900 °C, Surf. Coat. Technol., 2003, 166 (1), p 89-100
16. B. S. Sidhu and S. Prakash, Plasma Spray Coatings of Ni-20Cr on Boiler Tube Steel and Evaluation of Its Oxidation Behaviour at 900 °C in Air, J. Corros. Sci. Eng., 2003, 6, Paper 88.
17. 3Al Coatings on Boiler Tube Steels, Mater. Sci. Eng. A, 2004, 368 (1-2), p 149-158
18. B.S. Sidhu, D. Puri, and S. Prakash, Mechanical and Metallurgical Properties of Plasma Sprayed and Laser Remelted Ni-20Cr and Stellite-6 Coatings, J. Mater. Process. Technol., 2005, 159 (3), p 347-355
19. H.C. Chen, Z.Y. Liu, and Y.C. Chuang, Degradation of Plasma-Sprayed Alumina and Zirconia Coatings on Stainless Steel During Thermal Cycling and Hot Corrosion, Thin Solid Films, 1993, 223 (1), p 56-64
20. L.C. Erickson, R. Westergard, U. Wiklund, N. Axen, H.M. Hawthorne, and S. Hogmark, Cohesion in Plasma-Sprayed Coatings: A Comparison Between Evaluation Methods, Wear, 1998, 214, p 30-37
21. V.H. Hidalgo, F.J.B. Varela, and A.C. Menendez, Characterization and High Temperature Behaviour of Thermal Sprayed Coatings Used in Boilers, Proc. of the 15th Int. Thermal Spray Conf., May 25-29, Nice, France, 1998, p 617-621
22. F.J. Belzunce, V. Higuera, and S. Poveda, High Temperature Oxidation of HFPD Thermal-Sprayed MCrAlY Coatings, Mater. Sci. Eng. A, 2001, 297 (1-2), p 162-167
23. 2-NiCr Coatings Prepared by Plasma, Detonation and High-Velocity Oxyfuel Spraying, Proc. of the 7th National Thermal Spray Conf., Boston, MA, 1994, p 121-126
24. H. Chen and I.M. Hutchings, Abrasive Wear Resistance of Plasma-Sprayed Tungsten Carbide-Cobalt Coatings, Surf. Coat. Technol., 1998, 107, p 106-114
25. S.E. Sadique, A.H. Mullah, M.S. Islam, M.M. Ali, M.H.H. Megat, and S. Basri, High-Temperature Oxidation Behavior of Iron-Chromium-Aluminum Alloys, Oxid. Met., 2000, 54 (5-6), p 385-400
26. P.D. Miller and H.H. Krause, Factors Influencing the Corrosion of Boiler Steels in Municipal Incinerators, Corrosion, 1971, 27 (1), p 31-45
27. S. Srikanth, B. Ravikumar, S.K. Das, K. Gopalakrishna, K. Nandakumar, and P. Vijayan, Analysis of Failures in Boiler Tubes Due to Fireside Corrosion in a Waste Heat Recovery Boiler, Eng. Failure Anal., 2003, 10, p 59-66
28. H.E. Crossley, A. Poll, and F. Sweett, The Reduction of Sulphur Trioxide by Constituents of Boiler Flue Dust, J. Inst. Fuel, 1948, 21, p 207-209
29. Y. Longa-Nava, Y. S. Zhang, M. Takemoto, and R.A. Rapp, Hot Corrosion of Nickel-Chromium and Nickel-Chromium-Aluminum Thermal-Spray Coatings by Sodium Sulfate-Sodium Metavanadate Salt, Corrosion, 1996, 52 (9), p 680-689
30. G. Calvarin, R. Molins, and A.M. Huntz, Oxidation Mechanism of Ni-20Cr Foils and Its Relation to the Oxide-Scale Microstructure, Oxid. Met., 2000, 53 (1-2), p 25-48
31. H. Nickel, W.J. Quadakkers, and L. Singheiser, Analysis of Corrosion Layers on Protective Coatings and High Temperature Materials in Simulated Service Environments of Modern Power Plants Using SNMS, SIMS, SEM, TEM, RBS and X-Ray Diffraction Studies, Anal. Bioanal. Chem., 2002, 374, p 581-587
32. R.C. John, Slag, Gas and Deposit Thermochemistry in a Coal Gasifier, J. Electrochem. Soc., 1986, 133 (1), p 205-211
33. H.W. Nelson, H.H. Krause, E.W. Ungar, A.A. Putnam, C.J. Slunder, P.D. Miller, J.D. Hummel, and B.A. Landry, A Review of Available Information on Corrosion and Deposits in Coal- and Oil-Fired Boilers and Gas Turbines, Report of ASME Research Committee on Corrosion and Deposits from Combustion Gases, Pergamon Press and ASME, New York, 1959.
34. 2 Intermediate on the Combination Ability of Coatings, Surf. Coat. Technol., 2001, 140, p 231-237