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High-Temperature Oxidation and Smelt Deposit Corrosion of Ni-Cr-Ti Arc-Sprayed Coatings

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Abstract

High Cr content Ni-Cr-Ti arc-sprayed coatings have been extensively applied to mitigate corrosion in black liquor recovery boilers in the pulp and paper industry. In a previous article, the effects of key spray parameters on the coating’s microstructure and its composition were investigated. Three coating microstructures were selected from that previous study to produce a dense, oxidized coating (coating A), a porous, low oxide content coating (coating B), and an optimized coating (coating C) for corrosion testing. Isothermal oxidation trials were performed in air at 550 and 900 °C for 30 days. Additional trials were performed under industrial smelt deposits at 400 and 800 °C for 30 days. The effect of the variation in coating microstructure on the oxidation and smelt’s corrosion response was investigated through the characterization of the surface corrosion products, and the internal coating microstructural developments with time at high temperature. The effect of long-term, high-temperature exposure on the interaction between the coating and substrate was characterized, and the mechanism of interdiffusion was discussed.

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Acknowledgments

The authors gratefully acknowledge the support of Holster Engineering Company by supplying the wire and spraying the samples for this study. We would also like to thank Warren Blakemore for providing the smelt samples for this study and for his insight on the operation of industrial black liquor recovery boilers. The support provided by Professor Margaret Hyland in facilitating this study is gratefully appreciated.

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Authors and Affiliations

  1. School of Engineering and Advanced Technology, Massey University, Private Bag 102904, Auckland, 0745, New Zealand

    S. Matthews

  2. Department of Chemical and Materials Engineering, The University of Auckland, Private Bag 92019, Auckland Mail Centre, Auckland, 1142, New Zealand

    M. Schweizer

  3. Department of Surface and Materials Technology, Aalen University of Applied Sciences, Beethovenstraße 1, 73430, Aalen, Germany

    M. Schweizer

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  1. S. Matthews
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Correspondence to S. Matthews.

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Matthews, S., Schweizer, M. High-Temperature Oxidation and Smelt Deposit Corrosion of Ni-Cr-Ti Arc-Sprayed Coatings. J Therm Spray Tech 22, 932–946 (2013). https://doi.org/10.1007/s11666-013-9939-2

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  • DOI: https://doi.org/10.1007/s11666-013-9939-2

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