Abstract
Nowadays, wire-arc spraying is an attractive technique to deposit coatings for oxidation and corrosion protection. In this study, a new FeCrSiB-cored wire was designed to produce protective coatings for the components used in high temperature environment by wire-arc spraying. The microstructure, phase composition, microhardness, and high temperature corrosion behavior of the new coating were investigated in comparison with a FeCr coating and a commercial NiCrTi coating. The results showed that the FeCrSiB coating was composed of dense lamella with much fewer oxide inclusions than the FeCr and NiCrTi coatings. The microhardness of the FeCrSiB coating was the highest of the three coatings. Thermogravimetric analysis was used to evaluate the high temperature corrosion behavior of the coatings in mixed salt Na2SO4-25% K2SO4 environment at 650 °C under cyclic condition. It showed that the high temperature corrosion resistance of the FeCrSiB coating is significantly better than that of the FeCr coating and approaching to the commercial NiCrTi coating.
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-015-0244-0/MediaObjects/11666_2015_244_Fig1_HTML.gif)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-015-0244-0/MediaObjects/11666_2015_244_Fig2_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-015-0244-0/MediaObjects/11666_2015_244_Fig3_HTML.gif)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-015-0244-0/MediaObjects/11666_2015_244_Fig4_HTML.gif)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-015-0244-0/MediaObjects/11666_2015_244_Fig5_HTML.gif)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-015-0244-0/MediaObjects/11666_2015_244_Fig6_HTML.jpg)
Similar content being viewed by others
References
S.S. Chatha, H.S. Sidhu, and B.S. Sidhu, High-Temperature Behavior of a NiCr-Coated T91 Boiler Steel in the Platen Superheater of Coal-Fired Boiler, J. Therm. Spray Technol., 2013, 22(5), p 838-847.
M. Kaur, H. Singh, and S. Prakash, Surface Engineering Analysis of Detonation-Gun Sprayed Cr3C2-NiCr Coating Under High-Temperature Oxidation and Oxidation-Erosion Environments, Surf. Coat. Technol., 2011, 206(2-3), p 530-541.
M.A. Farrokhzad and T.I. Khan, High Temperature Oxidation of Nickel-Based Cermet Coatings Composed of Al2O3 and TiO2 Nanosized Particles, Oxid. Met., 2014, 81(1-2), p 267-285.
R. Li, Z. Zhou, D.Y. He, L.D. Zhao, and X.Y. Song, Microstructure and High-Temperature Oxidation Behavior of Wire-Arc Sprayed Fe-Based Coatings, Surf. Coat. Technol., 2014, 251, p 186-190.
V.H. Hidalgo, J.B. Varela, A.C. Mene´ndez, and S.P. Martı´nez, High Temperature Erosion Wear of Flame and Plasma-Sprayed Nickel-Chromium Coatings Under Simulated Coal-Fired Boiler Atmospheres, Wear, 2001, 247(2), p 214-222.
S. Paul and M.D.F. Harvey, Corrosion Testing of Ni Alloy HVOF Coatings in High Temperature Environments for Biomass Applications, J. Therm. Spray Technol., 2013, 22(2-3), p 316-327.
M. Kaur, H. Singh, and S. Prakash, Role of Detonation Gun Spray Cr3C2-NiCr Coating in Improving High Temperature Corrosion Resistance of SAE-213-T22 and SAE-347H Steel in Presence of Na2SO4-82%Fe2(SO4)3 Salt Deposits, Surf. Eng., 2010, 26(6), p 428-439.
Y. Bai, C.H. Ding, H.Q. Li, Z.H. Han, B.J. Ding, T.J. Wang, and L. Yu, Isothermal Oxidation Behavior of Supersonic Atmospheric Plasma-Sprayed Thermal Barrier Coating System, J. Therm. Spray Technol., 2013, 22(7), p 1201-1209.
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.
S. Pahlavanyali, A. Sabour, and M. Hirbod, The Hot Corrosion Behaviour of HVOF Sprayed MCrAlX Coatings Under Na2SO4 (+NaCl) Salt Films, Mater. Corros., 2003, 54(9), p 687-693.
M.R. Ramesh, S. Prakash, S.K. Nath, P.K. Sapra, and N. Krishnamurthy, Evaluation of Thermocyclic Oxidation Behavior of HVOF-Sprayed NiCrFeSiB Coatings on Boiler Tube Steels, J. Therm. Spray Technol., 2011, 20(5), p 992-1000.
J. Porcayo-Calderon, E. Brito-Figueroa, and J.G. Gonzalez-Rodriguez, Oxidation Behaviour of Fe-Si Thermal Spray Coatings, Mater. Lett., 1999, 38(1), p 45-53.
M. Student, Yu Dzioba, V. Hvozdets’kyi, H. Pokhmurska, B. Wielage, and T. Grund, High-Temperature Corrosion of Electric-Arc Coatings Sprayed from Powder Core Wires Based on the Fe-Cr-B-Al System, Mater. Sci., 2008, 44(5), p 693-699.
R. Li, D.Y. He, Z. Zhou, L.D. Zhao, and X.Y. Song, High Temperature Corrosion Behaviour of Wire Arc Sprayed Fe Based Coatings, Surf. Eng., 2014, 30(8), p 573-578.
T.S. Sidhu, S. Parkash, and R.D. Agrawal, Hot Corrosion Behaviour of HVOF-Sprayed NiCrBSi Coatings on Ni- and Fe-Based Superalloys in Na2SO4-60% V2O5 Environment at 900 °C, Acta Mater., 2006, 54(3), p 773-784.
Q.M. Wang, Y.N. Wu, P.L. Ke, H.T. Cao, J. Gong, C. Sun, and L.S. Wen, Hot Corrosion Behavior of AIP NiCoCrAlY(SiB) Coatings on Nickel Base Superalloys, Surf. Coat. Technol., 2004, 186(3), p 389-397.
K. Venugopal and M. Agrawal, Evaluation of Arc Sprayed Coatings for Erosion Protection of Tubes in Atmospheric Fluidized Bed Combustion (AFBC) Boilers, Wear, 2008, 264(1-2), p 139-145.
J. Zhou, J.K. Walleser, B.E. Meacham, and D.J. Branagan, Novel In Situ Transformable Coating for Elevated-Temperature Applications, J. Therm. Spray Technol., 2010, 19(5), p 950-957.
R. Luding, R. Thorpe, and R.V. Hinckley, The Development of Twin Wire Arc and HP/HVOF Sprayed Coatings for Coal-Fired Steam Generation Boiler, Adv. Mater. Process., 2010, 168(2), p 34-36.
T.S. Sidhu, S. Parkash, and R.D. Agrawal, Evaluation of Hot Corrosion Resistance of HVOF Coatings on a Ni-Based Superalloy in Molten Salt Environment, Mater. Sci. Eng. A, 2006, A430(1-2), p 64-78.
Acknowledgments
This study was financially supported by the National Natural Science Foundation of China (51301009), Beijing Natural Science Foundation (2142010), Specialized Research Fund for the Doctoral Program of Higher Education (3C009012201301) and Open Research Fund of State Key Laboratory (RERV 2014021).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Li, R., Zhou, Z., He, D. et al. Microstructure and High Temperature Corrosion Behavior of Wire-Arc Sprayed FeCrSiB Coating. J Therm Spray Tech 24, 857–864 (2015). https://doi.org/10.1007/s11666-015-0244-0
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-015-0244-0