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Comparative High Temperature Analysis of HVOF-Sprayed and Detonation Gun Sprayed Ni–20Cr Coating in Laboratory and Actual Boiler Environments

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Abstract

High-velocity-oxy-fuel (HVOF) spray and detonation-gun (D-gun) spray techniques were used to deposit Ni–20Cr coatings on a commonly used boiler steel ASTM-SAE 213-T22. The specimens, with and without coating, were subjected to molten salt (Na2SO4–60%V2O5) deposition in a laboratory furnace at 900 °C to determine hot-corrosion resistance. Specimens were also exposed to the superheater zone of a thermal power plant boiler at an average temperature of 700 °C under cyclic conditions to ascertain their erosion-corrosion (E-C) behavior. Mass-change measurements were taken to approximate the kinetics of corrosion and erosion-corrosion. In the case of E-C, the thickness lost data were also taken at the end of the exposure. The exposed specimens were characterized by X-ray diffraction (XRD) and field-emission scanning electron microscopy/energy dispersive spectroscopy (FE-SEM/EDS). The HVOF-sprayed coating was found to be intact during exposure to both given environments; whereas the D-gun coating showed spallation of its oxide scale during exposure to the molten salt environments. An overall analysis of the results indicated that the HVOF-sprayed Ni–20Cr coating should be a better choice for the given boiler applications.

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Authors and Affiliations

  1. RIMT-Institute of Engineering & Technology Mandi Gobindgarh, Punjab, India

    G. Kaushal

  2. Indian Institute of Technology Ropar, Rupnagar, Punjab, India

    H. Singh

  3. Indian Institute of Technology Roorkee, Roorkee, Uttarakhand, India

    S. Prakash

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  1. G. Kaushal
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  2. H. Singh
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  3. S. Prakash
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Correspondence to G. Kaushal.

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Kaushal, G., Singh, H. & Prakash, S. Comparative High Temperature Analysis of HVOF-Sprayed and Detonation Gun Sprayed Ni–20Cr Coating in Laboratory and Actual Boiler Environments. Oxid Met 76, 169–191 (2011). https://doi.org/10.1007/s11085-011-9245-7

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  • DOI: https://doi.org/10.1007/s11085-011-9245-7

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