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Arc-Sprayed Iron-Based Coatings for Erosion-Corrosion Protection of Boiler Tubes at Elevated Temperatures

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Abstract

Wire arc spraying is an economically attractive thermal spray process that is especially interesting for the protection of large-scale parts or constructions. This study presents the results of the development and investigation of a number of cored wires based on the Fe-Cr-Al system with minor addition of alloying elements (B, Mn, Ni, Si, Ti, Mg, etc.). The microstructure of the coatings, their electrochemical behavior, and isothermal oxidation performance over a temperature range of 20-700 °C were investigated. Erosion resistance at elevated temperatures was determined with a laboratory test unit under test conditions that have simulated the work conditions in fossil-fuel-fired boilers. It was established that the oxidation resistance and the gas-abrasive wear resistance of arc-sprayed coatings depend mostly on the coating microstructure and homogeneity of element distribution rather than on the general alloying level and microhardness of the coating. A new parameter for coating characterization, namely, the coefficient of chemical microheterogeneity, K CMH, is introduced to quantify this influence. Formation of the coating microstructure at elevated temperatures and its influence on the protection ability of the coating are discussed.

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Authors and Affiliations

  1. G.V. Karpenko Physico-Mechanical Institute of the National Academy of Sciences of Ukraine, Lviv, Ukraine

    Vasyl Pokhmurskii, Mykhailo Student, Volodymyr Gvozdeckii, Taras Stypnutskyy & Oleksandra Student

  2. Institute of Material Science and Engineering, Chemnitz University of Technology, Chemnitz, Germany

    Bernhard Wielage & Hanna Pokhmurska

Authors
  1. Vasyl Pokhmurskii
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  2. Mykhailo Student
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  3. Volodymyr Gvozdeckii
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  4. Taras Stypnutskyy
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  5. Oleksandra Student
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  6. Bernhard Wielage
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  7. Hanna Pokhmurska
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Correspondence to Hanna Pokhmurska.

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Pokhmurskii, V., Student, M., Gvozdeckii, V. et al. Arc-Sprayed Iron-Based Coatings for Erosion-Corrosion Protection of Boiler Tubes at Elevated Temperatures. J Therm Spray Tech 22, 808–819 (2013). https://doi.org/10.1007/s11666-013-9921-z

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  • DOI: https://doi.org/10.1007/s11666-013-9921-z

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