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Cited by 15High-Temperature Coating BehaviorsSurface Treatment and CoatingsCorrosion Behavior and Inhibition

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Characterization and hot corrosion behavior of D-gun sprayed Cr2O3-75% Al2O3 coated ASTM-SA210-A1 boiler steel in molten salt environment

Rani, Amita, Bala, Niraj, Gupta, C.M.·2017·Anti-Corrosion Methods and Materials
DOI 10.1108/acmm-09-2016-1712
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Abstract

Purpose Hot corrosion is the major degradation mechanism of failure of boiler and gas turbine components. The present work aims to investigate the hot corrosion resistance of detonation gun sprayed (D-gun) Cr2O3-75 per cent Al2O3 ceramic coating on ASTM-SA210-A1 boiler steel. Design/methodology/approach The coating exhibits nearly uniform, adherent and dense microstructure with porosity less than 0.8 per cent. Thermogravimetry technique is used to study the high temperature hot corrosion behavior of bare and coated boiler steel in molten salt environment (Na2SO4-60 per cent V2O5) at high temperature 900°C for 50 cycles. The corrosion products are analyzed by using X-ray diffraction, scanning electron microscopy (SEM) and field emission scanning electron microscope/energy-dispersive analysis (EDAX) to reveal their microstructural and compositional features for elucidating the corrosion mechanisms. Findings During investigations, it was found that the Cr2O3-75 per cent Al2O3 coating on Grade A-1 boiler steel is found to be very effective in decreasing the corrosion rate in the molten salt environment at 900°C. The coating has shown lesser weight gains along with better adhesiveness of the oxide scales with the substrate till the end of the experiment. Thus, coatings serve as an effective diffusion barrier to preclude the diffusion of oxygen from the environment into the substrate boiler steel. Research limitations/implications Therefore, it is concluded that the better hot corrosion resistance of the coating is due to the formation of desirable microstructural features such as very low porosity, uniform fine grains and the flat splat structures in the coating; as compared to the bare substrate under cyclic conditions. Practical implications This research is useful for coal-fired boilers and other power plant boilers. Social implications This research is useful for power generation plants. Originality/value There is no reported literature on hot corrosion behavior of Cr2O3-75 per cent Al2O3 coating deposited on the selected substrates by D-gun spray technique. The present work has been focused to study the influence of the Cr2O3-75 per cent Al2O3 coating developed with D-gun spraying technique on high temperature corrosion behavior of ASTM-SA210-A-1 boiler steel in an aggressive environment of Na2SO4-60 per cent V2O5 molten salt at 900°C under cyclic conditions.

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  • D-gunTM Cr2O3-Al2O3 coatings on T-22 boiler steel and 800H superalloy formed oxide scales of Al2O3 and Cr2O3 as protection against molten Na2SO4-V2O5 at 900 °C, resulting in intact coatings after 50 cycles of exposures.

    “Rani et al. [118, 119] studied the corrosion behaviours of D-gun™ Cr2O3–Al2O3 coatings on T-22 boiler steel and 800H superalloy in molten Na2SO4–V2O5 at 900 °C. Coatings on both the substrates formed oxide scales of Al2O3 and Cr2O3 as protection against the molten salt mixture, resulting in intact coatings after 50 cycles of exposures.”

    From High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review (2024) · cites this paper as [118]

  • The only ceramic that has been exploited D-gunTM applications is Cr2O3-Al2O3.

    “The only ceramic that has been exploited D-gun™ applications is Cr2O3–Al2O3 [118, 119].”

    From High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review (2024) · cites this paper as [118]

  • The weight gain of coated specimens after cyclic hot corrosion was less than the uncoated ones.

    “As a result, the weight gain of coated specimens after cyclic hot corrosion was less than the uncoated ones.”

    From High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review (2024) · cites this paper as [118]

  • The Kp values of coated T-22 and 800H specimens were 72.77 × 10-8 g2 cm−4 s−1 and 0.39 × 10−8 g2 cm−4 s−1, respectively.

    “The Kp values of coated T-22 and 800H specimens were 72.77 × 10–8 g2 cm−4 s−1 and 0.39 × 10–8 g2 cm−4 s−1, respectively.”

    From High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review (2024) · cites this paper as [118]

  • Kp of T-22 steel coated with the Cr2O3-Al2 was reduced to 0.06 × 10-8 g2 cm−4 s−1 and Kp of coated 800H superalloy was reduced to 0.24 × 10-8 g2 cm−4 s−1.

    “However, Kp of T-22 steel coated with the Cr2O3–Al2 was reduced to 0.06 × 10–8 g2 cm−4 s−1 and Kp of coated 800H superalloy was reduced to 0.24 × 10–8 g2 cm−4 s−1.”

    From High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review (2024) · cites this paper as [118]

Citations

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Metadata

Authors
Rani, A., Bala, N., & Gupta, C. M.
Affiliations
Punjab Technical University (IN)
ORCID
Bala, Niraj
Venue
Anti-Corrosion Methods and Materials
Publisher
Emerald
Published
2017-09-04
Volume
64
Issue
5
Pages
515-528
ISSN
0003-5599 (ISSN-L)
DOI
10.1108/acmm-09-2016-1712
OpenAlex
W2737752605
Cited by
15
References
2
Citations by year
2024: 2 · 2023: 5 · 2022: 1 · 2021: 3 · 2020: 1 · 2019: 1 · 2018: 2
FWCI
1.01
Type
journal article
Language
en
Open access
closed
Licence
www.emerald.com/insight/site-policies (tdm)
Locations
Anti-Corrosion Methods and Materials (publishedVersion)
Topics
  • Physical Sciences › Materials Science › Surfaces, Coatings and Films › High-Temperature Coating Behaviors
  • Physical Sciences › Engineering › Mechanical Engineering › Surface Treatment and Coatings
  • Physical Sciences › Materials Science › Materials Chemistry › Corrosion Behavior and Inhibition
Keywords
hot corrosion, detonation spraying, molten salt corrosion, Na2SO4-V2O5, oxide scale adhesion, diffusion barrier, coating porosity, corrosion products, coating microstructure, weight gain, power plant boilers

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