Thermal spray coatings are widely used to keep power plants running at full capacity. An example is the application of HVOF-sprayed CrC-NiCr to protect generating and superheater banks from sulfuric and vanadium gases. Other examples include the use of arc spraying to deposit high Cr content Ni alloy to extend the life of coal-fired boiler tubes and to apply amorphous work hardening coatings to surfaces in the flu gas path that are susceptible to high-temperature corrosion and wear.

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