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Characterization and High-Temperature Erosion Behaviour of HVOF Thermal Spray Cermet Coatings

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Abstract

High-velocity oxygen fuel (HVOF) thermal spray, carbide–cermet-based coatings are usually employed in high-temperature erosive and erosive–corrosive environments. Extensive literature is available on high-temperature erosion performance of HVOF coatings under moderate to low particle flux and velocities for application in boiler tubes. This research work presents the characterization and high-temperature erosion behaviour of Cr3C2-25NiCr and WC-10Co-4Cr HVOF-sprayed coatings. Coatings were formulated on the substrate steel of type AISI 304, commonly used for the fabrication of pulverized coal burner nozzles (PCBN). Erosion testing was carried out in high-temperature air-jet erosion tester after simulating the conditions akin to that prevailing in PCBN in the boiler furnace. The coatings were tested for erosion behaviour at different angles and temperatures by freezing other test parameters. Brittle erosion behaviour was depicted in erosion testing, and the coatings couldn’t restrain the erodent attacks to protect the substrate. High particle velocity and high particle flux were attributed to be the reasons of extensive erosive weight loss of the coatings. The surface morphology of the eroded specimens was analysed from back-scattered electron images to depict the probable mechanism of material removal. The coatings were characterized with optical microscopy, SEM-EDS analysis, XRD analysis, micro-hardness testing, porosity measurements, surface roughness testing and bond strength testing. The work was undertaken to investigate the performance of the selected coatings in highly erosive environment, so as to envisage their application in PCBNs for protection against material degradation. The coatings could only sustain in oblique impact erosion at room temperature and depleted fully under all other conditions.

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Acknowledgments

The work was funded by Department of Science and Technology (DST), Govt. of India, New Delhi, India, through a major research project entitled “Technological Innovations to Improve Degradation Resistance of Pulverized Coal Burner Nozzle (PCBN)”. The authors are highly grateful to DST for providing financial assistance to carry out this research work.

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  1. Mechanical Engineering Section, Yadavindra College of Engineering, Punjabi University G.K. Campus, Talwandi Sabo, Distt. Bathinda, Punjab, 151302, India

    Pardeep Kumar

  2. Department of Academics, Punjab Technical University, Jalandhar-Kapurthala Highway, Kapurthala, Punjab, 144601, India

    Buta Singh Sidhu

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  1. Pardeep Kumar
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Correspondence to Pardeep Kumar.

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Kumar, P., Sidhu, B.S. Characterization and High-Temperature Erosion Behaviour of HVOF Thermal Spray Cermet Coatings. J. of Materi Eng and Perform 25, 250–258 (2016). https://doi.org/10.1007/s11665-015-1818-1

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  • DOI: https://doi.org/10.1007/s11665-015-1818-1

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