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Optimization of Arc-Sprayed Ni-Cr-Ti Coatings for High Temperature Corrosion Applications

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Abstract

High Cr content Ni-Cr-Ti arc-spray coatings have proven successful in resisting the high temperature sulfidizing conditions found in black liquor recovery boilers in the pulp and paper industry. The corrosion resistance of the coatings is dependent upon the coating composition, to form chromium sulfides and oxides to seal the coating, and on the coating microstructure. Selection of the arc-spray parameters influences the size, temperature and velocity of the molten droplets generated during spraying, which in turn dictates the coating composition and formation of the critical coating microstructural features—splat size, porosity and oxide content. Hence it is critical to optimize the arc-spray parameters in order to maximize the corrosion resistance of the coating. In this work the effect of key spray parameters (current, voltage, spray distance and gas atomizing pressure) on the coating splat thickness, porosity content, oxide content, microhardness, thickness, and surface profile were investigated using a full factorial design of experiment. Based on these results a set of oxidized, porous and optimized coatings were prepared and characterized in detail for follow-up corrosion testing.

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Acknowledgments

The authors are thankful for the valuable information and support provided by Warren Blakemore on the operation and maintenance of black liquor recovery boilers. The support from Holster Engineering Ltd (NZ) in spraying the coatings for this work is also gratefully acknowledged. The support provided by Professor Margaret Hyland in facilitating this work 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, Auckland Mail Centre, University of Auckland, Private Bag 92019, 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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Correspondence to S. Matthews.

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Matthews, S., Schweizer, M. Optimization of Arc-Sprayed Ni-Cr-Ti Coatings for High Temperature Corrosion Applications. J Therm Spray Tech 22, 538–550 (2013). https://doi.org/10.1007/s11666-013-9914-y

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  • DOI: https://doi.org/10.1007/s11666-013-9914-y

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