Hot Corrosion Behavior of TWAS and HVOF NiCr-Based Coatings in Molten Salt
In order to extend the life of boilers by applying an anti-corrosion coating without the need to dismantle them, it is advisable to find coatings that can be applied using cheaper and portable techniques, such as Twin Wire Arc Spray technology (TWAS). In this study, we compare selected NiCr-based co...
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MDPI AG
2023-02-01
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| Online Access: | https://www.mdpi.com/1996-1944/16/4/1712 |
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| author | Kateřina Lencová Marie Frank Netrvalová Marek Vostřák František Lukáč Radek Mušálek Zdeněk Česánek Šárka Houdková |
| author_facet | Kateřina Lencová Marie Frank Netrvalová Marek Vostřák František Lukáč Radek Mušálek Zdeněk Česánek Šárka Houdková |
| author_sort | Kateřina Lencová |
| collection | DOAJ |
| description | In order to extend the life of boilers by applying an anti-corrosion coating without the need to dismantle them, it is advisable to find coatings that can be applied using cheaper and portable techniques, such as Twin Wire Arc Spray technology (TWAS). In this study, we compare selected NiCr-based coatings and two uncoated steel substrates (steel 1.7715 and 1.4903). Two coatings, Cr<sub>3</sub>C<sub>2</sub> - 25% NiCr and Hastelloy C-276 are deposited using High velocity oxygen-fuel technology (HVOF) and three coatings, NiCrTi, NiCrMo, and Inconel 625, are deposited using TWAS. In addition to the corrosion weight gain during 50 cycles of loading in an 18% Na<sub>2</sub>SO<sub>4</sub> and 82% Fe<sub>2</sub>(SO<sub>4</sub>)<sub>3</sub> salt environment at 690 °C evaluated using the gravimetric method, the microstructure and phase composition of the coatings were analyzed on the samples after the exposure in order to compare the properties and gain a deeper understanding of the corrosion kinetics. Coating cross-sections and free-surfaces were observed with a scanning electron microscope (SEM) with an energy-dispersive (EDX) system. The phase composition was investigated using X-ray diffraction (XRD) and Raman spectroscopy. No significant differences were observed between the TWAS and HVOF coating methods for the coatings compared. Due to the similar corrosion products found on all coatings, a very effective corrosion protective layer was formed on the surface, forming a barrier between the corrosive environment and the coating regardless of the used deposition technology. Therefore, for industrial use on the inner surface of coal-fired boilers we recommend NiCrTi, NiCrMo, or Inconel coatings prepared with the more cost-effective and portable TWAS technology. |
| first_indexed | 2024-03-11T08:29:56Z |
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| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-11T08:29:56Z |
| publishDate | 2023-02-01 |
| publisher | MDPI AG |
| record_format | Article |
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| spelling | doaj.art-f5b17cb121ec4d8f9015d72a8dd05a2c2023-11-16T21:53:30ZengMDPI AGMaterials1996-19442023-02-01164171210.3390/ma16041712Hot Corrosion Behavior of TWAS and HVOF NiCr-Based Coatings in Molten SaltKateřina Lencová0Marie Frank Netrvalová1Marek Vostřák2František Lukáč3Radek Mušálek4Zdeněk Česánek5Šárka Houdková6Research and Testing Institute Plzen, 30100 Pilsen, Czech RepublicResearch and Testing Institute Plzen, 30100 Pilsen, Czech RepublicResearch and Testing Institute Plzen, 30100 Pilsen, Czech RepublicInstitute of Plasma Physics of CAS, 18200 Prague, Czech RepublicInstitute of Plasma Physics of CAS, 18200 Prague, Czech RepublicResearch and Testing Institute Plzen, 30100 Pilsen, Czech RepublicResearch and Testing Institute Plzen, 30100 Pilsen, Czech RepublicIn order to extend the life of boilers by applying an anti-corrosion coating without the need to dismantle them, it is advisable to find coatings that can be applied using cheaper and portable techniques, such as Twin Wire Arc Spray technology (TWAS). In this study, we compare selected NiCr-based coatings and two uncoated steel substrates (steel 1.7715 and 1.4903). Two coatings, Cr<sub>3</sub>C<sub>2</sub> - 25% NiCr and Hastelloy C-276 are deposited using High velocity oxygen-fuel technology (HVOF) and three coatings, NiCrTi, NiCrMo, and Inconel 625, are deposited using TWAS. In addition to the corrosion weight gain during 50 cycles of loading in an 18% Na<sub>2</sub>SO<sub>4</sub> and 82% Fe<sub>2</sub>(SO<sub>4</sub>)<sub>3</sub> salt environment at 690 °C evaluated using the gravimetric method, the microstructure and phase composition of the coatings were analyzed on the samples after the exposure in order to compare the properties and gain a deeper understanding of the corrosion kinetics. Coating cross-sections and free-surfaces were observed with a scanning electron microscope (SEM) with an energy-dispersive (EDX) system. The phase composition was investigated using X-ray diffraction (XRD) and Raman spectroscopy. No significant differences were observed between the TWAS and HVOF coating methods for the coatings compared. Due to the similar corrosion products found on all coatings, a very effective corrosion protective layer was formed on the surface, forming a barrier between the corrosive environment and the coating regardless of the used deposition technology. Therefore, for industrial use on the inner surface of coal-fired boilers we recommend NiCrTi, NiCrMo, or Inconel coatings prepared with the more cost-effective and portable TWAS technology.https://www.mdpi.com/1996-1944/16/4/1712hot corrosionmolten saltNiCr-based coatingHVOFTWASX-ray diffraction |
| spellingShingle | Kateřina Lencová Marie Frank Netrvalová Marek Vostřák František Lukáč Radek Mušálek Zdeněk Česánek Šárka Houdková Hot Corrosion Behavior of TWAS and HVOF NiCr-Based Coatings in Molten Salt Materials hot corrosion molten salt NiCr-based coating HVOF TWAS X-ray diffraction |
| title | Hot Corrosion Behavior of TWAS and HVOF NiCr-Based Coatings in Molten Salt |
| title_full | Hot Corrosion Behavior of TWAS and HVOF NiCr-Based Coatings in Molten Salt |
| title_fullStr | Hot Corrosion Behavior of TWAS and HVOF NiCr-Based Coatings in Molten Salt |
| title_full_unstemmed | Hot Corrosion Behavior of TWAS and HVOF NiCr-Based Coatings in Molten Salt |
| title_short | Hot Corrosion Behavior of TWAS and HVOF NiCr-Based Coatings in Molten Salt |
| title_sort | hot corrosion behavior of twas and hvof nicr based coatings in molten salt |
| topic | hot corrosion molten salt NiCr-based coating HVOF TWAS X-ray diffraction |
| url | https://www.mdpi.com/1996-1944/16/4/1712 |
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