Abstract
In this research work, hot corrosion behavior of different Y2O3-reinforced Cr2O3 matrix-based composite coatings on boiler tube steel has been examined at elevated temperature. Hot corrosion tests are carried out under molten salt environment of Na2SO4 + 60% V2O5 salt mixture at 900 °C for 50 cycles. Each cycle was consisting of 1 h heating in a silicon carbide tubular furnace followed by 20 min of cooling. The coatings on samples were developed by plasma-sprayed process. The parabolic rate constants of coated steels are lower when compared to the uncoated substrate. The outcome of the experiment has indicated that highest corrosion resistance was shown by 20 wt.% Y2O3–Cr2O3, and 10 wt.% Y2O3–Cr2O3 composite coatings. The 20 wt.% Y2O3–Cr2O3, and 10 wt.% Y2O3–Cr2O3 coatings were able to reduce the corrosion rate of boiler steel by 85.58 and 83.84%, respectively, at 900 °C temperature.
Similar content being viewed by others
Availability of Data and Materials
All data have been included in this manuscript.
References
El Rayes MM, Abdo HS, Khalil KA (2013) Erosion–corrosion of cermet coating. Int J Electrochem Sci 8(1):1117–1137
Garip Y (2022) An investigation on the corrosion performance of Fe2CoCrNi0.5 based high entropy alloys. Corros Sci 206:110497
Garip Y, Garip Z, Ozdemir O (2020) Prediction modeling of Type-I hot corrosion performance of Ti–Al–Mo–X (X= Cr, Mn) alloys in (Na, K) 2SO4 molten salt mixture environment at 900 °C. J Alloy Compd 843:156010
Singh J, Vasudev H, Singh S (2020) Performance of different coating materials against high temperature oxidation in boiler tubes—a review. Mater Today Proc 26:972–978
Goyal DK, Singh H, Kumar H, Sahni V (2012) Slurry erosive wear evaluation of HVOF-spray Cr2O3 coating on some turbine steels. J Therm Spray Technol 21:838–851
Levy AV (1993) The erosion–corrosion of tubing steels in combustion boiler environments. Corros Sci 35(5–8):1035–1043
Chawla V, Chawla A, Puri D, Prakash S, Gurbuxani PG, Sidhu BS (2011) Hot corrosion & erosion problems in coal based power plants in India and possible solutions—a review. J Miner Mater Charact Eng 10(04):367
Kumar N, Kanwar R (2012) To study erosion behavior of Cr. Int J Emerg Technol 3(1):69–73
Garg BP, Kumar N (2013) Protection of SAE 213 T-22 boiler steel tube material with various power coatings using HVOF spray technique. J Environ Nanotechnol 2:30–36
Huttunen-Saarivirta E, Stott FH, Rohr V, Schütze M (2007) Erosion-oxidation behavior of chromized-aluminized 9% chromium steel under fluidized-bed conditions at elevated temperature. Oxid Met 68:113–132
Kamal S, Jayaganthan R, Prakash S, Kumar S (2008) Hot corrosion behavior of detonation gun sprayed Cr3C2–NiCr coatings on Ni and Fe-based superalloys in Na2SO4–60% V2O5 environment at 900 °C. J Alloy Compd 463(1–2):358–372
Singh H, Puri D, Prakash S (2005) Some studies on hot corrosion performance of plasma sprayed coatings on a Fe-based superalloy. Surf Coat Technol 192(1):27–38
Mannava V, Rao AS, Paulose N, Kamaraj M, Kottada RS (2016) Hot corrosion studies on Ni-base superalloy at 650 °C under marine-like environment conditions using three salt mixture (Na2SO4+ NaCl+ NaVO3). Corros Sci 105:109–119
Pawlowski L (2008) The science and engineering of thermal spray coatings. Wiley, New York
Singh A, Goyal K, Goyal R, Krishan B (2021) Hot corrosion behaviour of different ceramics coatings on boiler tube steel at 800 °C temperature. J Bio-and Tribo-Corros 7:1–9
Goyal A, Singh R, Singh G (2017) Study of high-temperature corrosion behavior of D-Gun spray coatings on ASTM-SA213, T-11 steel in molten salt environment. Mater Today Proc 4(2):142–151
Bhatia R, Singh H, Sidhu BS (2014) Hot corrosion studies of HVOF-sprayed coating on T-91 boiler tube steel at different operating temperatures. J Mater Eng Perform 23:493–505
Mittal R, Singh H (2020) Evaluation of the behavior of D-Gun sprayed coatings on T-11 boiler steel at 900 °C temperature. Mater Today Proc 26:549–555
Bala N, Singh H, Prakash S, Karthikeyan J (2012) Investigations on the behavior of HVOF and cold sprayed Ni–20Cr coating on T22 boiler steel in actual boiler environment. J Therm Spray Technol 21:144–158
Bala N, Singh H, Karthikeyan J, Prakash S (2013) Performance of cold sprayed Ni–20Cr and Ni–50Cr coatings on SA 516 steel in actual industrial environment of a coal fired boiler. Mater Corros 64(9):783–793
Rani A, Bala N, Gupta CM (2017) Accelerated hot corrosion studies of D-Gun-sprayed Cr2O3–50% Al2O3 coating on boiler steel and Fe-based superalloy. Oxid Met 88:621–648
Goyal K, Singh H, Bhatia R (2019) Hot-corrosion behavior of Cr2O3-CNT-coated ASTM-SA213-T22 steel in a molten salt environment at 700 °C. Int J Miner Metall Mater 26:337–344
Rani A, Bala N, Gupta CM (2017) Characterization and hot corrosion behavior of D-Gun sprayed Cr2O3–75% Al2O3 coated ASTM-SA210-A1 boiler steel in molten salt environment. Anti-Corros Methods Mater 64(5):515–528
Singh S, Goyal K, Goyal R (2016) Performance of Cr3C2–25 (Ni–20Cr) and Ni–20Cr coatings on T91 boiler tube steel in simulated boiler environment at 900 °C. Chem Mater Eng 4(4):57–64
Ullah I, Siddiqui MA, Liu H, Kolawole SK, Zhang J, Zhang S et al (2020) Mechanical, biological, and antibacterial characteristics of plasma-sprayed (Sr, Zn) substituted hydroxyapatite coating. ACS Biomater Sci Eng 6(3):1355–1366
Yang X, Dong S, Zeng J, Zhou X, Jiang J, Deng L, Cao X (2019) Sliding wear characteristics of plasma-sprayed Cr2O3 coatings with incorporation of metals and ceramics. Ceram Int 45(16):20243–20250
Singh S, Goyal K, Bhatia R (2022) A review on protection of boiler tube steels with thermal spray coatings from hot corrosion. Mater Today Proc 56(1):379–383
Parkash J, Saggu HS, Vasudev H (2022) A short review on the performance of high velocity oxy-fuel coatings in boiler steel applications. Mater Today Proc 50:1442–1446
Patil VG, Somasundaram B, Kandaiah S, Kumar S (2022) High temperature corrosion behavior of high velocity oxy fuel sprayed NiCrMoFeCoAl-30% SiO2 and NiCrMoFeCoAl-30% Cr2O3 composite coatings on ASTM SA213-T22 steel in a coal-fired boiler environment. Int J Eng 35(7):1416–1427
Goyal K, Singh H, Bhatia R (2018) Cyclic high temperature corrosion studies of carbon nanotubes-Cr2O3 composite coatings on boiler steel at 900 °C in molten salt environment. Anti-Corros Methods Mater 65(6):646–657
Ozkan D (2023) Structural characteristics and wear, oxidation, hot corrosion behaviors of HVOF sprayed Cr3C2–NiCr hardmetal coatings. Surf Coat Technol 457:129319
Garip Y, Ozdemir O (2019) Comparative study of the oxidation and hot corrosion behaviors of TiAl–Cr intermetallic alloy produced by electric current activated sintering. J Alloy Compd 780:364–377
Garip Y, Ozdemir O (2020) Corrosion behavior of the resistance sintered TiAl based intermetallics induced by two different molten salt mixture. Corros Sci 174:108819
Zhang Y, Wu H, Yu X, Tang D (2022) Role of Cr in the high-temperature oxidation behavior of CrxMnFeNi high-entropy alloys at 800 °C in air. Corros Sci 200:110211
Cui C, Wu M, Miao X, Zhao Z, Gong Y (2022) Microstructure and corrosion behavior of CeO2/FeCoNiCrMo high-entropy alloy coating prepared by laser cladding. J Alloy Compd 890:161826
Funding
Authors declare that they have not received any funding from any source.
Author information
Authors and Affiliations
Contributions
DS and KG contributed to conception of work, experimental design, experimentation, data analysis, and draft of manuscript. CS and HS contributed to experimentation, dara analysis, and manuscript draft.
Corresponding author
Ethics declarations
Conflict of interest
Authors declare that they have no conflict of interest, and they have also no financial interest.
Ethical approval
Not applicable.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Singh, D., Goyal, K., Singh, C. et al. Effect of Y2O3 Reinforcement on Hot Corrosion of Cr2O3-Based Composite Coatings at Elevated Temperature. J Bio Tribo Corros 9, 52 (2023). https://doi.org/10.1007/s40735-023-00773-6
Received:
Revised:
Accepted:
Published:
DOI: https://doi.org/10.1007/s40735-023-00773-6