Skip to main content
SpringerLink
Log in

Elevated Temperature Corrosion Studies of AlCrN and TiAlN Coatings by PAPVD on T91 Boiler Steel

  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

The present investigation discusses the hot corrosion behavior of AlCrN and TiAlN nano-coatings on T91 boiler steel by PAPVD process subjected to molten salt of Na2SO4-60%V2O5 at 900 °C for 50 cycles. Surface and cross-sectional studies were performed by AFM, SEM/EDS and XRD techniques to understand the corrosion kinetics and mechanism. T91 bare boiler steel as well as TiAlN-coated specimen has shown higher internal oxidation as well as weight gain. The better corrosion resistance of AlCrN-coated specimen has been observed by virtue of higher availability of Cr and Al in the oxide scale as well as adherent and dense coating. The betterment of AlCrN coating can be attributed to low internal oxidation as well as movement of Cr and Al toward oxide scale to form protective corrosion barriers.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

References

  1. S.S. Chatha, H. Singh, and B.S. Sidhu, High Temperature Hot Corrosion Behavior of NiCr and Cr3C2-NiCr Coatings on T91 Boiler Steel in an Aggressive Environment at 750°C, Surf. Coat. Technol., 2012, 206, p 3839–3850

    Article  Google Scholar 

  2. M. Kumar, H. Singh, and N. Singh, Production of Nanocrystalline Ni-20Cr Coatings for High-Temperature Applications, J. Therm. Spray Technol., 2014, 23(4), p 692–707

    Article  Google Scholar 

  3. T.S. Sidhu, S. Prakash, and R.D. Agrawal, Hot Corrosion Performance of a NiCr Coated Ni-Based Alloy, Scr. Mater., 2006, 55, p 179–182

    Article  Google Scholar 

  4. M. Kaur, H. Singh, and S. Prakash, High-Temperature Behavior of a High-Velocity Oxy-Fuel Sprayed Cr3C2-NiCr Coating, Metall. Mater. Trans. A, 2012, 43(8), p 2979–2993

    Article  Google Scholar 

  5. N. Rana, R. Jayaganthan, and S. Prakash, Stepwise Depletion of Coating Elements as a Result of Hot Corrosion of NiCrAlY Coatings, J. Mater. Eng. Perform, 2014, 23(2), p 1–15

    Article  Google Scholar 

  6. G. Kaushal, H. Singh, and S. Prakash, Comparative High Temperature Analysis of HVOF-Sprayed and Detonation Gun Sprayed Ni-20Cr Coating in Laboratory and Actual Boiler Environment, Oxid. Met., 2011, 76, p 169–191

    Article  Google Scholar 

  7. V. Chawla, Microstructural Characteristics and Mechanical Properties of Nanostructured and Conventional TiAlN and AlCrN Coatings on ASTM-SA210 Grade A-1 Boiler Steel, ISRN Corrosion. 2013, p 1–14

  8. V. Chawla, A. Chawla, B.S. Sidhu, S. Prakash, and D. Puri, Oxidation Behavior of Nanostructured TiAlN and AlCrN Thin Coatings on ASTM-SA213-T-22 Boiler Steel, J. Miner. Mater. Charact. Eng., 2010, 9(11), p 1037–1057

    Google Scholar 

  9. H. Luo, D. Goberman, L. Shaw, and M. Gell, Indentation Fracture Behavior of Plasma-Sprayed Nanostructured Al2O3-13wt.%TiO2 Coatings, Mater. Sci. Eng. A, 2003, 386, p 237–245

    Article  Google Scholar 

  10. J.S. Grewal, B.S. Sidhu, and S. Prakash, High Temperature Erosion Performance of Nanostructured and Conventional TiAlN Coatings on AISI-304 Boiler Steel Substrate, Trans. Ind. Inst. Met., 2014, 67(6), p 889–902

    Article  Google Scholar 

  11. J. He and J.M. Schoenung, Nanostructured Coatings, Mater. Sci. Eng. A, 2002, 336, p 274–319

    Article  Google Scholar 

  12. T. Grosdidier, A. Tidu, and H.L. Liao, Nanocrystalline Fe-40Al Coating Processed by Thermal Spraying of Milled Powder, Scr. Mater., 2001, 44, p 387–393

    Article  Google Scholar 

  13. J. Lin, B. Mishra, J.J. Moore, and W.D. Sproul, A Study of the Oxidation Behavior of CrN and CrAlN Thin Films in Air Using DSC and TGA Analyses, Surf. Coat. Technol., 2008, 202, p 3272–3283

    Article  Google Scholar 

  14. B.R. Marple, J. Voyer, J.F. Bisson, and C. Moreau, Thermal Spraying of Nanostructured Cermet Coatings, J. Mater. Process. Technol., 2001, 117, p 418–423

    Article  Google Scholar 

  15. D. Ghosh, H. Roy, S. Das, and S.K. Mitra, Nanostructured CeO2 Coating for High Temperature Oxidation Protection, Surf. Eng., 2016, 32(9), p 397–403

    Article  Google Scholar 

  16. J.L. Endrino, G.S. Fox-Robinovich, and C. Gey, Hard AlTiN, AlCrN PVD Coating for Machining of Austenitic Stainless Steel, Surf. Coat. Technol., 2006, 200, p 6840–6845

    Article  Google Scholar 

  17. V.N. Shukla, R. Jayaganthan, and V.K. Tewari, Degradation Behavior of Nanostructured Coatings Deposited by High-Velocity Arc Spraying Process in an Actual Environment of a Coal-Fired Boiler, JOM, 2013, 65(6), p 784–791

    Article  Google Scholar 

  18. N. Rana, M.M. Mahapatra, R. Jayaganthan, and S. Prakash, High-Temperature Oxidation and Hot Corrosion Studies on NiCrAlY Coatings Deposited by Flame-Spray Technique, J. Therm. Spray Technol., 2015, 24(5), p 769–777

    Article  Google Scholar 

  19. Y. Bourhis and C. St. John, Na2SO4 and NaCl Induced Hot Corrosion of Six Nickel-Base Superalloys, Oxid. Met., 1975, 9(6), p 506–528

    Article  Google Scholar 

  20. B.S. Sidhu and S. Prakash, Studies on the Behaviour of Stellite-6 as Plasma Sprayed and Laser Remelted Coatings in Molten Salt Environment at 900 °C Under Cyclic Conditions, J. Mater. Process. Technol., 2006, 172, p 52–63

    Article  Google Scholar 

  21. R. Mittal and B.S. Sidhu, Microstructures and Mechanical Properties of Dissimilar T91/347H Steel Weldments, J. Mater. Process. Technol., 2015, 220, p 76–86

    Article  Google Scholar 

  22. B.S. Sidhu and S. Prakash, Evaluation of the Corrosion Behaviour of Plasma-Sprayed Ni3Al Coatings on Steel in Oxidation and Molten Salt Environment at 900 °C, Surf. Coat. Technol., 2003, 166(1), p 89–100

    Article  Google Scholar 

  23. N. Bala, H. Singh, J. Karthikeyan, and S. Prakash, Performance of Cold Sprayed Ni-20Cr and Ni-50Cr Coatings on SA516 Steel in Actual Industrial Environment of a Coal Fired Boiler, Mater. Corr., 2013, 46(9), p 783–793

    Google Scholar 

  24. S.S. Chatha, H. Singh, and B.S. Sidhu, The Effects of Post-Treatment on the Hot Corrosion Behavior of the HVOF-Sprayed Cr3C2-NiCr Coating, Surf. Coat. Technol., 2012, 206, p 4212–4224

    Article  Google Scholar 

  25. V. Chawla, D. Puri, S. Prakash, and B.S. Sidhu, Corrosion Behavior of Nanostructured TiAlN and AlCrN Hard Coatings on Superfer 800H Superalloy in Simulated Marine Environment, J. Miner. Mater. Charact. Eng., 2009, 8(9), p 693–700

    Google Scholar 

  26. R. Mittal and B.S. Sidhu, Oil-Ash Corrosion Resistance of Dissimilar T22/T91 Welded Joint of Super Heater, J. Mater. Eng. Perform., 2015, 24(2), p 670–682

    Article  Google Scholar 

  27. A. Ul-Hamid, Diverse Scaling Behavior of the Ni-20Cr Alloy, Mater. Chem. Phys., 2003, 80, p 135–142

    Article  Google Scholar 

  28. D. Mudgal, S. Kumar, S. Singh, and S. Prakash, Corrosion Behavior of Bare, Cr3C2-25%(NiCr), and Cr3C2-25%(NiCr) + 0.4%CeO2-Coated Superni 600 Under Molten Salt at 900 °C, J. Mater. Eng. Perform., 2014, 23(11), p 3805–3818

    Article  Google Scholar 

  29. Y. Ding, Effects of Elevated Temperature Exposure on the Microstructural Evolution of Ni(Cr)-Cr 3 C 2 Coated 304 Stainless Steel, Ph.D. Thesis, University of Nottingham, 2009, p 191

  30. K. Fujita, Research and Development of Oxidation, Wear and Corrosion Resistant Materials at High Temperature by Surface Modification Using Ion Processing, Surf. Coat. Technol., 2005, 196, p 139–144

    Article  Google Scholar 

  31. P.E.H. Hovsepian, C. Reinhard, and A.P. Ehiasarian, CrAlYN/CrN Superlattice Coatings Deposited by the Combined High Power Impulse Magnetron Sputtering/Unbalanced Magnetron Sputtering Technique, Surf. Coat. Technol., 2006, 201, p 4105–4110

    Article  Google Scholar 

  32. W.Y.H. Liew, Low-Speed Milling of Stainless Steel with TiAlN Single Layer and TiAlN/AlCrN Nano-Multilayer Coated Carbide Tools Under Different Lubrication Conditions, Wear, 2010, 269, p 617–631

    Article  Google Scholar 

  33. M. Seiersten and P. Kofstad, The Effect of SO3 on Vanadate-Induced Hot Corrosion, High Temp. Technol., 1987, 5(3), p 115–122

    Article  Google Scholar 

  34. R. Mittal and B.S. Sidhu, Studies on Microstructural Properties of GTAW Weldment of Ferritic Steels at CAMS2014 International Conference of Combined Australian Materials Societies, University of Sydney, Sydney, 2014

  35. R. Mittal and B.S. Sidhu, Microstructural and Mechanical Characterization of Different Zones of T91/T22 Weldment, Int. J. Surf. Eng. Mater. Technol., 2014, 4(2), p 45–49

    Google Scholar 

  36. S. Kamal, R. Jayaganthan, and S. Prakash, Evaluation of Cyclic Hot Corrosion Behaviour of Detonation Gun Sprayed Cr3C2-25%NiCr Coatings on Nickel and Iron-Based Super Alloys, Surf. Coat. Technol., 2009, 203, p 1004–1013

    Article  Google Scholar 

  37. N. Bala, H. Singh, and S. Prakash, High Temperature Oxidation Studies of Cold-Sprayed Ni-20Cr and Ni-50Cr Coatings on SAE 213-T22 Boiler Steel, Appl. Surf. Sci., 2009, 255(15), p 6862–6869

    Article  Google Scholar 

  38. Y. Mishin and C. Herzig, Diffusion in the Al-Ti System, Acta Mater., 2000, 48(3), p 589–623

    Article  Google Scholar 

  39. B.S. Sidhu, D. Puri, and S. Prakash, Characterization of Plasma Sprayed and Laser Remelted NiCrAlY Bond Coats and Ni3Al Coating on Boiler Tube Steels, Mater. Sci. Eng. A, 2004, 368, p 149–158

    Article  Google Scholar 

  40. S. Kamal, R. Jayaganthan, and S. Prakash, Hot Corrosion Studies of Detonation-Gun-Sprayed NiCrAlY+0.4%CeO2 Coated Superalloys in Molten Salt Environment, J. Mater. Eng. Perform., 2011, 20, p 1068–1077

    Article  Google Scholar 

  41. Y.C. Chim, X.Z. Ding, X.T. Zeng, and S. Zang, Oxidation Resistance of TiN, CrN, TiAlN and CrAlN Coatings Deposited by Lateral Rotating Cathode Arc, Thin Solid Films, 2009, 517, p 4845–4849

    Article  Google Scholar 

  42. H. Willmann, P.H. Mayrhofer, P.O.A. Persson, A.E. Reiter, L. Hultman, and C. Mitterer, Thermal Stability of Al-Cr-N Hard Coatings, Scr. Mater., 2006, 54(11), p 1847–1851

    Article  Google Scholar 

  43. H. Holleck, Material Selection of Hard Coatings, J. Vac. Sci. Technol. A, 1986, 4, p 2661–2668

    Article  Google Scholar 

  44. A.E. Reiter, C. Mitterer, and B. Sartory, Oxidation of Arc-Evaporated Al1−xCrxN Coatings, J. Vac. Sci. Technol. A, 2007, 25, p 711–720

    Article  Google Scholar 

  45. R. Mittal, L. Goyal, and B.S. Sidhu, Study of Corrosion Behavior of SA213T91 Boiler Steel in the Environment of Air and Molten Salt of Na2SO4-60%V2O5 at 900 °C, Int. J. Res. Mech. Eng. Technol., 2013, 3(2), p 58–63

    Google Scholar 

  46. M. Zandrahimi, J. Vatandoost, and H. Ebrahimifar, Pack Cementation Coatings for High-Temperature Oxidation Resistance of AISI, 304 Stainless Steel, J. Mater. Eng. Perform., 2012, 21(10), p 2074–2079

    Article  Google Scholar 

  47. C. Xu and W. Gao, Pilling-Bedworth Ratio for Oxidation of Alloys, Mater. Res. Innov., 2000, 3, p 231–235

    Article  Google Scholar 

  48. N.B. Pilling and R.E. Bedworth, The Oxidation of Metals at High Temperatures, J. Inst. Met., 1923, 29, p 529–591

    Google Scholar 

  49. F.D. Quarto, K. Doblhofer, and H. Gerjscher, Instability of Anodically Formed TiO2 Layers, Electrochim. Acta, 1978, 23, p 195–201

    Article  Google Scholar 

  50. D.M. Johnson, D.P. Whittle, and J. Stringer, Mechanisms of Na2SO4-Induced Accelerated Oxidation, Corros. Sci., 1975, 15, p 739–751

    Google Scholar 

  51. I. Gurrappa, Hot Corrosion Behaviour of CM247LC Alloy in Na2SO4 and NaCl Environments, Oxid. Met., 1999, 51(5/6), p 353–382

    Article  Google Scholar 

  52. M. Arndt and T. Kacsich, Performance of New AlTiN Coating in Dry and High Speed Cutting, Surf. Coat. Technol., 2003, 163–164, p 674–680

    Article  Google Scholar 

Download references

Acknowledgments

The corresponding author would like to acknowledge I. K. Gujral Punjab Technical University, Jalandhar, for providing the requisite platform for conducting the research work.

Author information

Authors and Affiliations

  1. I. K. Gujral Punjab Technical University, Kapurthala, Punjab, India

    Lucky Goyal & Vikas Chawla

  2. Maharaja Ranjit Singh Punjab Technical University, Bathinda, Punjab, India

    Jasbir Singh Hundal

Authors
  1. Lucky Goyal
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Vikas Chawla
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jasbir Singh Hundal
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Lucky Goyal.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Goyal, L., Chawla, V. & Hundal, J.S. Elevated Temperature Corrosion Studies of AlCrN and TiAlN Coatings by PAPVD on T91 Boiler Steel. J. of Materi Eng and Perform 26, 5481–5494 (2017). https://doi.org/10.1007/s11665-017-2972-4

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-017-2972-4

Keywords

Search

Navigation