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Investigations on the Behavior of HVOF and Cold Sprayed Ni-20Cr Coating on T22 Boiler Steel in Actual Boiler Environment

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Abstract

High temperature corrosion accompanied by erosion is a severe problem, which may result in premature failure of the boiler tubes. One countermeasure to overcome this problem is the use of thermal spray protective coatings. In the current investigation high velocity oxy-fuel (HVOF) and cold spray processes have been used to deposit commercial Ni-20Cr powder on T22 boiler steel. To evaluate the performance of the coatings in actual conditions the bare as well as the coated steels were subjected to cyclic exposures, in the superheater zone of a coal fired boiler for 15 cycles. The weight change and thickness loss data were used to establish kinetics of the erosion-corrosion. X-ray diffraction, surface and cross-sectional field emission scanning electron microscope/energy dispersive spectroscopy (FE-SEM/EDS) and x-ray mapping techniques were used to analyse the as-sprayed and corroded specimens. The HVOF sprayed coating performed better than its cold sprayed counterpart in actual boiler environment.

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Acknowledgments

Harpreet Singh et al. thankfully acknowledge the research grant from Council of Scientific and Industrial Research, New Delhi (File No. 22(0441)/07/EMR-II, Dated October 23, 2007) for carrying out the R&D work on “Investigations on the role of cold spray coatings to control hot corrosion of steam generating plants.” The authors express their sincere thanks to ASB Industries, Inc, Barbeton, Ohio, USA and Guru Gobind Singh Super Thermal Power Plant, Ropar (India) for their kind co-operation during this work.

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Authors and Affiliations

  1. Baba Banda Singh Bahadur Engineering College, Fatehgarh Sahib, Punjab, India

    Niraj Bala

  2. Indian Institute of Technology Ropar, Rupnagar, India

    Harpreet Singh

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

    Satya Prakash

  4. ASB Industries, Barberton, OH, USA

    J. Karthikeyan

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  1. Niraj Bala
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Bala, N., Singh, H., Prakash, S. et al. Investigations on the Behavior of HVOF and Cold Sprayed Ni-20Cr Coating on T22 Boiler Steel in Actual Boiler Environment. J Therm Spray Tech 21, 144–158 (2012). https://doi.org/10.1007/s11666-011-9698-x

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