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Development and Characterization of High-Velocity Flame Sprayed Ni/TiO2/Al2O3 Coatings on Hydro Turbine Steel

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Abstract

Nickel-based coatings deposited by high-velocity flame spray (HVFS) process have been widely used to overcome the slurry erosion in a hydro turbine, where many turbine components are subjected to severe erosion failure. In this work, new kind of multi-dimensional Ni-40TiO2 and Ni-20TiO2-20Al2O3 coatings consisting of nanostructured and micron-sized particles of TiO2 and Al2O3 were developed by HVFS process on CA6NM(13Cr4Ni) turbine steel. The in-depth characterization of the synthesized nanostructured powders, prepared coating compositions and the deposited coating was done through dynamic light scattering, scanning electron microscopy, energy-dispersive spectroscopy and x-ray diffraction techniques. The mechanical and microstructural properties of the as-sprayed specimens were evaluated and discussed in this paper. The results showed that the multi-dimensional Ni-40TiO2 coating possessed lower porosity (0.8-2.0%), higher avg. microhardness (605 ± 37 HV0.1), and better bond strength (66.4 MPa) than the Ni-20TiO2-20Al2O3 coating.

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Acknowledgment

The authors thankfully acknowledge all the essential research facilities required for the completion of this project provided by Indian Institute of Technology Ropar, India, and Indian Institute of Technology, Roorkee. The authors would like to express sincere thanks to IKG, Punjab Technical University, Punjab, India, for supporting this research work.

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Authors and Affiliations

  1. I.K. Gujral Punjab Technical University, Jalandhar, India

    Vibhu Sharma

  2. Baba Banda Singh Bahadur Engineering College, Fatehgarh Sahib, India

    Manpreet Kaur & Sanjeev Bhandari

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  1. Vibhu Sharma
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Correspondence to Manpreet Kaur.

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Sharma, V., Kaur, M. & Bhandari, S. Development and Characterization of High-Velocity Flame Sprayed Ni/TiO2/Al2O3 Coatings on Hydro Turbine Steel. J Therm Spray Tech 28, 1379–1401 (2019). https://doi.org/10.1007/s11666-019-00918-5

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