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Effect of Carbide Dissolution on Chlorine Induced High Temperature Corrosion of HVOF and HVAF Sprayed Cr3C2-NiCrMoNb Coatings

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Abstract

Highly corrosion- and wear-resistant thermally sprayed chromium carbide (Cr3C2)-based cermet coatings are nowadays a potential highly durable solution to allow traditional fluidized bed combustors (FBC) to be operated with ecological waste and biomass fuels. However, the heat input of thermal spray causes carbide dissolution in the metal binder. This results in the formation of carbon saturated metastable phases, which can affect the behavior of the materials during exposure. This study analyses the effect of carbide dissolution in the metal matrix of Cr3C2-50NiCrMoNb coatings and its effect on chlorine-induced high-temperature corrosion. Four coatings were thermally sprayed with HVAF and HVOF techniques in order to obtain microstructures with increasing amount of carbide dissolution in the metal matrix. The coatings were heat-treated in an inert argon atmosphere to induce secondary carbide precipitation. As-sprayed and heat-treated self-standing coatings were covered with KCl, and their corrosion resistance was investigated with thermogravimetric analysis (TGA) and ordinary high-temperature corrosion test at 550 °C for 4 and 72 h, respectively. High carbon dissolution in the metal matrix appeared to be detrimental against chlorine-induced high-temperature corrosion. The microstructural changes induced by the heat treatment hindered the corrosion onset in the coatings.

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Acknowledgements

The work has been done within the DIMECC HYBRIDS (Hybrid Materials) program. We gratefully acknowledge the financial support from the Finnish Funding Agency for Innovation (Tekes) and the participating companies. A special thank goes also to Mr. Mikko Kylmälahti of Tampere University of Technology for spraying the HVOF and HVAF coatings, and Dr. Tech. Lucio Azzari and Dr. Tech. Matteo Maggioni for their support with the MatLab scripts.

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Authors and Affiliations

  1. Laboratory of Materials Science, Tampere University of Technology, Tampere, Finland

    D. Fantozzi, V. Matikainen, H. Koivuluoto & P. Vuoristo

  2. Valmet Technologies Ltd., Tampere, Finland

    M. Uusitalo

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  1. D. Fantozzi
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  2. V. Matikainen
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  3. M. Uusitalo
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  4. H. Koivuluoto
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  5. P. Vuoristo
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Correspondence to D. Fantozzi.

Additional information

This article is an invited paper selected from presentations at the 2017 International Thermal Spray Conference, held June 7-9, 2017, in Düsseldorf, Germany, that has been expanded from the original presentation.

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Fantozzi, D., Matikainen, V., Uusitalo, M. et al. Effect of Carbide Dissolution on Chlorine Induced High Temperature Corrosion of HVOF and HVAF Sprayed Cr3C2-NiCrMoNb Coatings. J Therm Spray Tech 27, 220–231 (2018). https://doi.org/10.1007/s11666-017-0645-3

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