Performance of cold sprayed Ni‐20Cr and Ni‐50Cr coatings on SA 516 steel in actual industrial environment of a coal fired boiler
Abstract
Abstract Power plants are one of the major industries suffering from severe erosion–corrosion (E‐C) problems resulting in substantial losses. One way of tackling this problem is by the use of thermal spray coatings. In the current investigation a new emerging technique i.e. cold spray coating process was used to deposit Ni‐20Cr and Ni‐50Cr powder on SA 516 (grade 70) boiler steel. The bare as well as the coated steels were subjected to cyclic experimental studies, in the superheater zone of a coal fired boiler. Weight change, thickness loss, XRD, FE‐SEM/EDS and X‐ray mapping techniques were used to analyse the eroded‐corroded specimens. The uncoated steel showed weight gain after exposure in the actual boiler environment, whereas, for the coated steels there was initial weight loss followed by negligible weight change. Based upon thickness loss data the cold‐sprayed Ni‐50Cr coating was found to provide better E‐C resistance than the Ni‐20Cr coating.
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Ni-50Cr shows a superior performance to Ni-20Cr because of its higher content of Cr and better microhardness.
“Bala et al. found that Ni-50Cr shows a superior performance to Ni-20Cr because of its higher content of Cr and better microhardness [115].”
From A review on molten sulfate salts induced hot corrosion (2021) · cites this paper as [115]
Cold-sprayed Ni-20Cr and Ni-50Cr coatings reduced corrosion-erosion rate by 58% and 72%, respectively, in a coal-fired boiler for 1500 h.
“The cold sprayed Ni-20Cr and Ni-50Cr coatings reduced corrosion–erosion rate by 58% and 72%, respectively.”
From High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review (2024) · cites this paper as [136]
The microhardness of the as-sprayed Ni-50Cr (469 Hv) was higher than the Ni-20Cr counterpart (221 Hv) due to higher chromium content that could form a hard Cr2O3 phase during high temperature exposure.
“The microhardness of the as-sprayed Ni-50Cr (469 Hv) was higher than the Ni-20Cr counterpart (221 Hv) due to higher chromium content that could form a hard Cr2O3 phase during high temperature exposure.”
From High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review (2024) · cites this paper as [136]
The corrosion resistance of cold-sprayed Ni-50Cr was superior to a Ni-20Cr counterpart owing to the higher chromium content that enabled formation of protective oxides.
“The corrosion resistance of cold-sprayed Ni-50Cr was superior to a Ni-20Cr counterpart owing to the higher chromium content that enabled formation of protective oxides.”
From High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review (2024) · cites this paper as [136]
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- Authors
- Bala, N., Singh, H., Karthikeyan, J., & Prakash, S.
- Affiliations
- Indian Institute of Technology Ropar (IN)
- Indian Institute of Technology Roorkee (IN)
- Corresponding author
- Singh, H.
- Venue
- Materials and Corrosion
- Publisher
- Wiley
- Published
- 2012-03-02
- Volume
- 64
- Issue
- 9
- Pages
- 783-793
- ISSN
- 0043-2822 (ISSN-L)
- 0947-5117
- 1521-4176
- OpenAlex
- W2048883113
- Cited by
- 21
- References
- 24
- Citations by year
- 2025: 2 · 2024: 3 · 2023: 4 · 2022: 2 · 2021: 1 · 2020: 2 · 2019: 1 · 2018: 1 · 2017: 1 · 2016: 1 · 2015: 2 · 2014: 1
- FWCI
- 1.61
- Type
- journal article
- Language
- en
- Open access
- closed
- Locations
- Materials and Corrosion (publishedVersion)
- Funders
- Council of Scientific and Industrial Research, New Delhi (File No. 22(0441)/07/EMR-II)
- Topics
- Physical Sciences › Engineering › Aerospace Engineering › High-Temperature Coating Behaviors
- Physical Sciences › Environmental Science › Ecological Modeling › Erosion and Abrasive Machining
- Physical Sciences › Engineering › Mechanical Engineering › Surface Treatment and Coatings
- Keywords
- cold spray coating, Ni-Cr coatings, boiler steel, erosion-corrosion, coal-fired boilers, superheater, coating thickness loss, weight gain, protective coatings
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