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Characterization and High-Temperature Oxidation Behavior of Cold-Sprayed Ni-20Cr and Ni-50Cr Coatings on Boiler Steels

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Abstract

Microstructure and mechanical properties of cold-spray coatings are usually required in order to explore the potential industrial application of the latter. This article demonstrates the successful formulation of Ni-20Cr and Ni-50Cr coatings on two boiler steels, namely, SAE 213-T22 and SA 516 steel by cold-spray process. The microstructure, coating thickness, phase formation, and microhardness properties of the coatings were evaluated. The coatings were subjected to cyclic heating and cooling cycles at an elevated temperature of 1173.15 K (900 °C) to ascertain their high-temperature oxidation behavior. Moreover, these cyclic exposures can give useful information regarding the adhesion of the coatings with the substrate steels. Of all the coatings, the Ni-50Cr coating on SA 516 steel had a maximum average hardness value of 469 Hv. As observed from the surface field emission–scanning electron microscopy (FE-SEM) analysis, the coatings were found to have nearly dense microstructure with the sprayed particles in interlocked positions. It was concluded that the cold-spray process is suitable for spraying the preceding powders onto the given boiler steels to produce nearly dense and low oxide coatings. The coatings, in general, were found to follow the parabolic rate of oxidation and were successful in maintaining their surface contact with their respective substrate steels.

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Acknowledgments

The authors thankfully acknowledge the research grant from the Council of Scientific and Industrial Research, New Delhi (File No. 22(0441)/07/EMR-II, dated October 23, 2007), for carrying out the R&D work on “Investigations on the role of cold-spray coatings to control hot corrosion of steam generating plants.” The authors express their sincere thanks to ASB Industries, Inc. (Barbeton, OH) and Guru Gobind Singh Super Thermal Power Plant (Ropar, India) for their kind cooperation during this work.

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Authors and Affiliations

  1. Baba Banda Singh Bahadur Engineering College, Fatehgarh Sahib, Punjab, India

    Niraj Bala (Assistant Professor)

  2. School of Mechanical, Materials and Energy Engineering, Indian Institute of Technology Ropar, Rupnagar, India

    Harpreet Singh (Assistant Professor)

  3. Metallurgical and Materials Engineering Department, Indian Institute of Technology Roorkee, Uttrakhand, India

    Satya Prakash (Professor)

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  1. Niraj Bala
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Correspondence to Niraj Bala.

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Manuscript submitted September 21, 2010.

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Bala, N., Singh, H. & Prakash, S. Characterization and High-Temperature Oxidation Behavior of Cold-Sprayed Ni-20Cr and Ni-50Cr Coatings on Boiler Steels. Metall Mater Trans A 42, 3399–3416 (2011). https://doi.org/10.1007/s11661-011-0759-z

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