Due to their thermal expansion coefficient being close to those of ferritic steels, NiAl atmospheric plasma spraying (APS)-coatings have been chosen to be tested in chloridizing atmosphere. A new type of quasi-stability diagram which couples thermodynamic and kinetic approaches was developed to define the stability domains of the pure metals aluminium and nickel in dynamic chlorine-and oxygen-containing atmospheres. NiAl APS-coatings (300 mm) with low porosity on steels were applied and tested in an atmosphere containing 0.2 v/o chlorine and 3 ppm oxygen. After 280 h of exposure one quarter of the outer coating was transformed into a protective alumina layer. Much nickel depletion, due to the evaporation of nickel chlorides, was observed.
Corrosion and wear in the hot gas area of thermal energy plants are severe problems, which often cause premature damage of components. In general, the most components of plants are made of materials, which are not stable under corrosive conditions. For corrosion protection (and also wear protection) and lifetime extension of these components, coatings with more resistant materials are applied. Because of the high concentration of corrosive species and the alternating composition of the atmosphere near to the components, the waste incineration plant is the ''worst case'' of high temperature corrosion. Nowadays, the most usual coating process to protect pipes in the waste incineration plants is cladding. In the last few years, alternative processes are under investigation because cladding is very cost-intensive. The specific costs of thermal spraying are much lower than those of cladding. In addition, the coating by thermal spraying reduces the risk of the dilution of substrate and coating material, different materials can be combined (e.g. metal alloys, ceramics) and the thickness of the layer for an acceptable resistance according to corrosion and wear can be drastically reduced. Thermal spraying has the potential to create cost-efficient coatings to protect components in the critical zones of incineration plants.Since many years, ATZ Entwicklungszentrum is involved in the development and/or advancement of materials, technologies and applications of thermal spraying for corrosion and/or wear protection in thermal energy plants. The main focuses of the investigations are layers for components in high temperature areas of waste incineration plants. On the basis of the present results, different coatings (metal alloys, ceramics) and different spray technologies (e.g. HVOF, APS) have been tested by different strategies (corrosion tests under laboratory scale, air cooled material probes inside the hot gas area of an incineration plant and coated pipes in operation as part of the superheater of incineration plants). This paper will give an overview about the current results of these corrosion tests, in which the focus are the investigations with material probes. First results showed that with the combination of different thermal sprayed layers a significant corrosion protection can be achieved.
Chlorine gas is widely encountered in chemical industries, as well as in waste incinerators and plastic/polymer decomposition mills. The presence of chlorine may significantly reduce the life-time of the components. Under chlorine-based atmospheres, the process of scale formation may be considerably affected and the presence of chlorine usually impedes the formation of a long term protective dense oxide scale. Based on thermodynamic calculations and previous investigations, NiAl and NiAlMo APS-coatings were produced to be used as protection for conventional steels against chlorine corrosion. Indeed, thermodynamic diagrams showed that molybdenum should have a positive behaviour in “reducing”-chloridizing atmospheres, whereas aluminium has a positive behaviour in “oxidizing”-chloridizing atmospheres. Coatings of approximatively 300 μm thickness were thermally sprayed on Armco Iron and on a commercial ferritic 18 Cr steel. This work presents the corrosion behaviour of NiAl and NiAlMo APS-coatings under chlorine-based atmospheres at 800°C. In addition, metallographic characterisation as well as EPMA investigations of the coating cross sections were carried out before and after the corrosion tests.
TiN reinforced Ti coatings were produced by using the arc spraying process. TiN hard phases were synthesized during spraying using Ar/N2 reactive atomizing gas. The spray process was realised in an air atmosphere with a shrouded gun and in a chamber with closed loop Ar/N2-gas atmosphere. The content of TiN phases in Ti-coatings was increased by rising the N2-amount in atomizing gas during spraying. Sprayed coatings obtained a graded hardness ranging from 450HV0.1 near the substrate up to 650HV0.1 near the top (mean values). TiN-particle precipitations exhibited micro hardness up to 1350HV0.1. Structure investigations of manufactured coatings proved that they consist of pure titanium, titanium nitrides and small amounts of titanium oxides. Wear resistance of the coatings, tested by Taber Abraser and Pin on Disc, decreases from the coating surface to the substrate. According to Kesternich test, Ti/TiN-arc sprayed coatings exhibit good corrosion resistance.
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