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Hot corrosion behaviour of plasma and d-gun sprayed coatings on t91 steel used in boiler applications
Open accessAbstract
Material degradation by salt induced hot corrosion is a serious threat to Coal fired Boiler components. Corrosion resistant thermal spray coatings is a proven solution for this problem. Thiswork compares the hot corrosion behaviour of a NiCoCrAlY coating on T91 boiler steel deposited using two different thermal spray methods namely Atmospheric Plasma Spray (APS) and Detonation Gun (D-Gun) spray. The coated samples were exposed to 650°C for 100 cycles (1 cycle being 1 hour holding plus 20 minutes cooling in air) in a thermal cycling furnace under a mixed deposit containing Na 2 SO 4, K 2 SO 4 and Fe 2 O 3 to simulate the real time coal ash environment. The exposed coatings were examined using FESEM/EDS and XRD to analyze the extent and nature of corrosion attack. The results indicate that the D-Gun sprayed coatings provided superior corrosion resistance over their APS sprayed counterparts. NiO and Spinel oxide NiCr 2 O 4 which offers corrosion resistance were formed in both the coatingswith the APS sprayed coatingbeing rich in the fast growing NiO which affected its corrosion performance. The enhanced corrosion resistance of the D-Gun sprayed coatings was attributed to its dense microstructure with minimal porosity and good intersplat bonding which minimized corrosion ingress.
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“The better corrosion resistance of D-gun™ NiCoCrAlY coating was attributed to a denser microstructure with 0.9% porosity compared to 2.1% porosity of the APS coating, see Fig. 21.”
From High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review (2024) · cites this paper as [127]
In the citing paper
“Both coatings formed spinel NiCr2O4 that provided protection against molten salt attack, but the corrosion resistance of D-gun™ coating was superior.”
From High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review (2024) · cites this paper as [127]
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Research works printed but not linked: 11
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High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review
Khantisopon, K., Singh, S., Jitputti, J., Berndt, C. C., & Ang, A. S. M. (2024) · High Temperature Corrosion of Materials · doi:10.1007/s11085-024-10251-0 · Cited by 30
Metadata
- Authors
- Sundaresan, C., Rajasekaran, B., Sivakumar, G., & Rao, D. S.
- Affiliations
- International Advanced Research Centre for Powder Metallurgy and New Materials (IN)
- Venue
- IOP Conference Series: Materials Science and Engineering
- Publisher
- IOP Publishing
- Published
- 2020-06-01
- Volume
- 872
- Issue
- 1
- Pages
- 012092
- ISSN
- 1757-8981 (ISSN-L)
- 1757-899X
- OpenAlex
- W3037340847
- Cited by
- 13
- References
- 0
- Citations by year
- 2026: 2 · 2025: 3 · 2024: 1 · 2023: 3 · 2022: 1 · 2021: 3
- FWCI
- 2.58
- Type
- conference paper
- Language
- en
- Open access
- diamond
- doi.org
- Licence
- Locations
- IOP Conference Series Materials Science and Engineering (publishedVersion, cc-by)
- Topics
- Physical Sciences › Materials Science › Surfaces, Coatings and Films › High-Temperature Coating Behaviors
- Physical Sciences › Engineering › Mechanical Engineering › Surface Treatment and Coatings
- Physical Sciences › Engineering › Mechanical Engineering › High Temperature Alloys and Creep
- Keywords
- hot corrosion, atmospheric plasma spraying, detonation spraying, T91 steel, NiCoCrAlY coating, coal-fired boilers, coal ash, thermal spray coatings, NiO formation, coating microstructure, porosity, interparticle bonding, corrosion resistance
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