Effect of additions of TiC and Re on high temperature corrosion performance of cold sprayed Ni–20Cr coatings

Singh, Harpreet; Bala, Niraj; Kaur, Narinder; Sharma, Sanjeev K.; Kim, Deuk Young; Prakash, S.

doi:10.1016/j.surfcoat.2015.08.002

Cited by 19 publications

(6 citation statements)

References 33 publications

(47 reference statements)

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“…The corrosion attack on boiler steels was significantly reduced by adding TiC to the coating. [98] between the mild steel substrate and the directly deposited SS316, even when introducing Fe powders to the SS316. The cracking at the substrate might have been caused by the thermal shock normally overcome by substrate preheating while cracking at the interface might have required an interlayer to transition between dissimilar material properties.…”

Section: Boilersmentioning

confidence: 99%

“…Preheating can significantly improve the microstructure and internal stress build-up when fabricating FGMs because it impacts the rate of cooling of the deposited layer by avoiding locked-in stresses that can initiate crack formation and residual stresses, leading to grain refinement and enhancement of microhardness properties. It enables the realisation of homogenous FGM clads with defect-free microstructures [95,97,98]. For instance, Banait et al [171] employed preheating the substrate to 400 °C before directed energy deposition of Ni-Cr-B-Si and SS316L functionally graded layers.…”

Section: Processing Of Functionally Graded Coatings For Heat Exchange...mentioning

confidence: 99%

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The potential use of laser cladded functionally graded materials to mitigate degradation in boiler tube heat exchangers for power plant applications: A review

Morake,

Mutua,

Ruthandi

et al. 2023

Surface Engineering

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Surface modification is essential to safeguard heat exchangers from premature failure spurred by deterioration mechanisms such as corrosion and wear, which diminish performance. Meanwhile, modifying some substrates with dissimilar materials is challenging due to a mismatch in material properties. Moreover, individual alloy coatings on substrates are usually insufficient in the required material properties, leading to accelerated failure of equipment, especially in power plant industries. This article summarised the knowledge base on functionally graded materials (FGMs) while emphasising how this promising class of novel materials can reduce deterioration. Additionally, laser cladding is established to be a suitable technique for processing FGMs. A particular focus is laid on the laser beam interaction with the FGM and expounding on the processing and material parameters that affect the microstructural properties of FGMs. The development prospects for processing FGMs with superior clad quality characteristics to increase boiler pipes' service life and performance are also highlighted.

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Section: Boilersmentioning

confidence: 99%

Section: Processing Of Functionally Graded Coatings For Heat Exchange...mentioning

confidence: 99%

The potential use of laser cladded functionally graded materials to mitigate degradation in boiler tube heat exchangers for power plant applications: A review

Morake,

Mutua,

Ruthandi

et al. 2023

Surface Engineering

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“…From Table 6, it is concluded that cold-sprayed Ni–50Cr and Ni– 20Cr–TiC–Re coatings on SA516 and T22 steel is a better option to provide maximum resistance against oxidation and hot corrosion, respectively [31,32].…”

Section: Preventive Measures To Combat High-temperature Degradationmentioning

confidence: 99%

Performance of thermal-sprayed coatings to combat hot corrosion of coal-fired boiler tube and effect of process parameters and post-coating heat treatment on coating performance: a review

Kumar

Handa

Chawla

et al. 2021

Surface Engineering

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High-temperature corrosion of coal-fired boiler parts such as water walls and superheated tubes poses a serious threat to the efficiency of the thermal power plant. To overcome this, numbers of corrosion control techniques are commonly employed. But, a dense and defectfree coating deposited by the thermal spray technique has shown promising result to combat hot corrosion. Although open or closed porosity in distinct thermal spray coatings can originate from distinct factors such as partial or totally un-molten particles, inadequate flow or fragmentation of the molten particle at impact, non-optimal spray angle and entrapped gas. But, this can still only be prevented by coating post-treatment. Hence, in this paper, authors have reviewed the performance of distinct coatings deposited by diverse thermal spray processes. Then, the effect of distinct process parameters and heat treatments on microstructure and mechanical properties of coatings is described. Finally, the best coatings are suggested to combat maximum hot corrosion of boiler tubes.

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“…In order to know more about the research progress of anticorrosion coatings, the detailed statistical classification of the adopted techniques in the literature were carried out. The statistical data were derived from 94 kinds of coatings in more than 60 literature contributions, − all of which focused on the corrosion-resistant coatings in the range of 400–900 °C. Therefore, it can be considered that these coatings have the potential for corrosion resistance in power plants.…”

Section: Corrosion-resistant Coatings To Protect Heat Transfer Tubesmentioning

confidence: 99%

“…Relative proportions of various technologies used in bench-scale corrosion resistance, on the basis of 94 kinds of coatings in more than 60 literature contributions. − …”

Section: Corrosion-resistant Coatings To Protect Heat Transfer Tubesmentioning

confidence: 99%

Application of Coatings to Alleviate Fireside Corrosion on Heat Transfer Tubes during the Combustion of Low-Grade Solid Fuels: A Review

et al. 2020

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To address the energy and environmental issues related to the use of traditional fossil fuels, the thermal utilization of low-grade solid fuels such as low-rank coal, biomass, and municipal solid waste has gradually attracted much attention. During the combustion of the low-grade solid fuels, one of the major operation problems is the fireside corrosion on heat transfer tubes, which easily causes the frequent replacement of tubes and shutdown of boilers, largely reducing the energy and economic performances. In this review, the causes and mechanisms of corrosion were first clarified to provide a basis for mitigating the losses induced by the fireside corrosion, followed by the introduction of the preparation and properties of coatings, which show great potential to resist the invasion of corrosive species by attaching the reinforced surface to the tubes. To demonstrate the feasibility of the coating for hightemperature corrosion resistance, 94 kinds of coatings in more than 60 literature contributions were statistically analyzed. It was found that over 90% of anticorrosion coatings were prepared from thermal spraying techniques, and approximately three-quarters of the anticorrosion coatings were made of NiCr-based alloys. Many methods were reported to evaluate the corrosion resistance of coatings in literature, including mass gain/loss method, ash deposition method, contact angle method, and ash adhesion method. As for exploring the anticorrosion mechanisms of coatings, it was found that the protection was achieved by the formation of dense oxide scale, such as Cr 2 O 3 , NiO, MoO 2 , and so on. Furthermore, the application status of coatings in power plants was also summarized. According to the pilot-scale tests listed in literature, the obvious similarity is that the adopted technologies were mainly High velocity oxy-fuel (HVOF) spraying or cold spraying techniques, with almost all of the coated materials being NiCr-based alloys as well as a small portion of Fe/Co-based alloys. This indicates that the NiCr-based coatings prepared by HVOF spraying technique have been widely applied in power plants. In order to promote the large-scale application of anticorrosion coatings, it is prospective to focus on several key research aspects: (1) predicting the corrosion conditions from fuel compositions, (2) developing costeffective coatings, (3) establishing the systematic evaluation methods by laboratory tests, (4) achieving in-depth understanding of the anticorrosion mechanisms, and (5) conducting a comprehensive economic analysis.

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Effect of additions of TiC and Re on high temperature corrosion performance of cold sprayed Ni–20Cr coatings

Cited by 19 publications

References 33 publications

The potential use of laser cladded functionally graded materials to mitigate degradation in boiler tube heat exchangers for power plant applications: A review

The potential use of laser cladded functionally graded materials to mitigate degradation in boiler tube heat exchangers for power plant applications: A review

Performance of thermal-sprayed coatings to combat hot corrosion of coal-fired boiler tube and effect of process parameters and post-coating heat treatment on coating performance: a review

Application of Coatings to Alleviate Fireside Corrosion on Heat Transfer Tubes during the Combustion of Low-Grade Solid Fuels: A Review

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