Comparative High-Temperature Corrosion Behavior of Ni-20Cr Coatings on T22 Boiler Steel Produced by HVOF, D-Gun, and Col
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NTRODUCTION
HOT corrosion is a serious problem in high-temperature applications such as boilers, gas turbines, waste incinerations, diesel engines, coal gasification plants, chemical plants, and other energy generation systems.[1] One method of hot corrosion prevention is to coat the alloy with a protective layer, which has been adopted in the current investigation. This is the preferred approach, even when relatively hot corrosion-resistant alloys are used.[2] The concern to develop and investigate the performance of various coating compositions has become a major area of research. The numerous variants of high-temperature coatings that are in use today may be categorized into three generic types: diffusion, overlay, and thermal barrier coatings.[2] In the service environment, the coating forms an oxide surface layer which ideally inhibits corrosion. To a degree, the oxide surface layer can be selected according to the environment, and the coating is designed to serve as a reservoir for the element forming the surface oxide. Performance of the surface coatings depends on composition and characteristics of feed stock powders as well as coating deposition process and its parameters. GAGANDEEP KAUSHAL, Assistant Professor, is with the Mechanical Engineering Section, Yadavindra College of Engineering, Punjabi University, Guru Kashi Campus, Talwandi Sabo, Distt., Bathinda, 151302 Punjab, India. Contact e-mail: gagankaushal@ yahoo.com NIRAJ BALA, Assistant Professor, is with the Mechanical Engineering Department, Baba Banda Singh Bahadur Engineering College, Fatehgarh Sahib, 140407 Punjab, India. NARINDER KAUR, Technical-Executive, and HARPREET SINGH, Associate Professor, are with the Indian Institute of Technology Ropar, Rupnagar, 140001 Punjab, India. SATYA PRAKASH, Professor Emeritus, is with the Indian Institute of Technology Roorkee, Roorkee, Uttarakhand, India. Manuscript submitted December 26, 2012. Article published online September 17, 2013 METALLURGICAL AND MATERIALS TRANSACTIONS A
Thermal spray processes represent an important and cost-effective technique for tailoring the surface properties of engineering components with a view to enhance their durability and performance under a variety of operating conditions. Thermal spraying has developed faster due to progress in the advancement of materials, and modern coating technology. Among the various techniques of thermal spraying, high velocity oxy-fuel (HVOF) thermal spray process has gained popularity as a viable technology for in situ applications, wear and corrosion management and dimensional restoration, mainly because of its important benefits such as high bond strength, low porosity and low stress coatings.[3,4] HVOF spray technique enables higher kinetic energy of the particulates and lower melting coating materials that enable particle-flattening in the plastic state.[5–9] However, its application for high-temperature corrosion protection is a relatively recent concern, especially for the steam-generating plants. Detonation gun spray (D-gun) coatings are know
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