The present work evaluates the oxidation and hot corrosion resistance of high velocity oxy-fuel (HVOF) sprayed WC-NiCrFeSiB coating deposited on Ni-based superalloy (Superni 75) and Fe-based superalloy (Superfer 800H). The coated as well as uncoated specimens were exposed to air and molten salt (Na 2 SO 4 -25%NaCl) environment at 800 °C under cyclic conditions. The thermogravimetric technique was used to establish the kinetics of corrosion. The corrosion products were characterized using the combined techniques of X-ray diffraction (XRD), scanning electron microscopy (SEM) and electron probe micro analyser (EPMA). The WC-NiCrFeSiB coating provides necessary resistance against oxidation and hot corrosion to both the nickel and iron based superalloys in the given environmental conditions at 800 °C. The oxides of active elements of the coatings, formed in the surface scale as well as at the boundaries of nickel and tungsten rich splats, have contributed for the oxidation and hot corrosion resistance of WC-NiCrFeSiB coatings, as these oxides act as barriers for the diffusion/penetration of the corrosive species through the coatings.

Hot corrosion tests have been conducted on Ni- and Cr-based laser coatings, a high-velocity oxy-fuel (HVOF) sprayed coating and various wrought alloys covered with a synthetic salt of Na 2 SO 4 -V 2 O 5 and exposed at 650°C for 1000 h in air. Coating microstructures and reaction product layers were analyzed with scanning electron microscope (SEM) and energy dispersive spectrometer (EDS). The hot corrosion resistance of tested specimen was evaluated by measuring its mean thickness loss. Generally, wrought alloys, HVOF coating and Cr-based laser coatings suffered from selective corrosion beneath salt film, that is, distinct Cr-depleted layer was formed at alloy/salt interface. Cr-based laser coatings exhibited extended solid solubility and they transformed towards equilibrium condition. Cr-rich phases enriched further with Cr and they were prone to corrosion. Low diluted laser coatings and HVOF coating were more resistant to hot corrosion than commonly used industrial standard alloy, Nimonic 80A. Ni-based laser coating exhibited resistance equivalent to Cr-based coatings and superior to corresponding wrought alloy.

Solid-particle erosion of metals and alloys at elevated temperatures is one of the main reasons of the damage of components used in the energy production and utilization industries. Application of protective coating systems can be an attractive and economically reasonable solution for preventing the failure and increasing the durability of the components working in severe conditions of high-temperature corrosion and erosion. However, thermal spraying of intermetallic materials that have excellent high-temperature corrosion resistance is limited because of their low ductility. Present work reports the results of the investigation of abrasion wear resistance at elevated temperatures of combined coatings, which include the intermetallic layer. Such iron aluminide layers have been formed as a result of diffusion during the heat post-treatment of arc-prayed metallic coatings combining Fe- and Al-based layers. Post-treatment of arc-sprayed coatings was carried out by means of infrared radiation and induction heating. It was shown that the abrasion resistance of the developed coating tested at elevated temperatures (T > 500 °C) is considerably higher than that of low-alloyed steel and some nickel-based alloys and depends on the test load condition. The high performance of intermetallic-based graded coatings at elevated temperatures makes them interesting for applications as a low-cost erosion-corrosion-resistant material.

Partially stabilized zirconia (8Y2O3-ZrO2) coatings were studied as thick thermal barrier coatings (TTBCs) for diesel engine applications. To improve the hot corrosion resistance of TTBCs the 1 mm thick yttria stabilized zirconia coating was densified with aluminum phosphate based sealant. Combined with better hot corrosion resistance other benefits obtained with sealing treatment are improved adhesion as well as increased mechanical properties of the ceramic layer. Three aluminum phosphate based sealants were investigated with varying viscosity level. Different sealant viscosities were used to optimize the level of sealant penetration into the coating. Sealant penetration and the violence of the reaction were determined by XRD, SEM/EDS and optical microscopy. The hardness profile from bond coat to the surface of the top layer was determined. Coating microstructure and phase structure were characterized by optical microscopy and by X-ray diffraction. Microhardness and porosity were determined. Residual stress states were measured by X-ray based stress analyzer. Bond strength of the coatings was determined with tensile test equipment. To simulate the diesel engine combustion conditions, hot corrosion tests were performed for the sealed TTBCs. Hot corrosion resistance of the coating was tested in isothermal exposure of 60Na2SO4 - 40V2O5 melt for 48 hours at 600 °C.

Hot corrosion behavior of Thermal Barrier Coatings (TBCs) has been studied by comparison between double layer coatings and graded coatings. Two types of oxide ceramics, 8 mass % Y 2 O 3 -ZrO 2 (8YZ) and 2CaOSiO 2 -15mass% CaOZrO 2 (C 2 S-15 CZ), with a bond coating of NiCrAlY were applied to metallic substrates in this study. After a hot corrosion test by V 2 O 5 -Na 2 SO 4 corrosive ashes, hot corrosion behavior of TBC has been investigated by visual inspection, metallography, X-ray diffraction and EPMA. The C 2 S-15%CZ coating reacted with V 2 O 5 only where it was in direct contact with the material. The affected area from the reaction was limited to the coating surface where V 2 O 5 existed. The coating showed adequate hot corrosion-resistance. It was found on the 8YZ coating that Y 2 O 3 , the stabilizing component, particularly reacts with V 2 O 5 and loses its function; this led to partial spalling of the coating. It was observed that the durability of the double layer TBC was largely influenced by the performance of a corrosion resistant NiCrAlY undercoat which provided protection against corrosive components penetrating through the ceramic topcoat. It was observed that the graded coating degraded due to oxidation of NiCrAlY particles which independently existed near the coating surface and affected the durability of TBC.

The unusual effects of plasma sprayed coating on the fire-side of evaporator tubes located in an oil-fired steam generating boiler are discussed. The main heat transfer surfaces are constructed by heat exchanger tubes, evaporator tubes and superheaters. Maintenance to prevent of the boiler failure or the preserve heat exchanger effectiveness is a very important factor in the operation of boiler facilities. In a boiler which employs heavy gravity oil as a fuel, plasma sprayed Ni-Cr alloy has often been applied to boiler tubes for the relief of hot corrosion by combustion gas. However, the circulation of boiler water causes an internal deposit to form on the inner wall of evaporator tubes. The internal deposit generates excess heat load against the tubes. As the overheating of the tubes often causes the evaporator tubes to fail, they are chemically cleaned periodically. In this paper, the influence of Ni-Cr plasma sprayed coating for the heat flux, which dominates the formation of the internal deposit, is investigated. Ni-Cr plasma sprayed coating is substitutionally hot corrosion resistant and is a composite coating into which the fuel ash containing a vanadium or sulfur compound are interstitially penetrated and solidified. It is derived that the existence of the coating on the fire-side of the evaporator tubes normalizes the heat load in their inner walls. Moreover, the suppression of internal deposit formation decreases the frequency of chemical cleaning for tubes. The dual effects of plasma sprayed coating for hot corrosion resistance in the fire side and the suppression of internal deposit on the water side of the tubes are reported.

Ti(Al,O)/Al 2 O 3 based composite powders with three different compositions were produced by high energy milling, sintering and grounding. High velocity oxy-fuel (HVOF) spraying was used to coat these powders onto Ti-6Al-4V alloy samples. High temperature oxidation and hot corrosion behaviour of the coatings was studied in dry air and Na 2 SO 4 + NaCl vapour, respectively. The results showed that Ti(Al,O)/Al 2 O 3 coatings have a much improved oxidation and hot corrosion resistance compared to the substrate Ti-6Al-4V alloy. The oxide formed on the surface of the coatings after high temperature exposure is composed of a mixture of Al 2 O 3 and TiO 2 . The oxide scales have excellent adhesion to the coatings, showing superior scale spallation resistance. Microstructural analysis suggested that the Al 2 O 3 particles could act as a diffusion barrier to O and Ti therefore reducing the oxidation rate. The Al 2 O 3 phase also forms an interlocking network penetrating throughout the oxide scale, reinforcing the fragile TiO 2 containing scale. It is believed this composite system can provide a new generation of coatings to Ti based alloys, raising the application temperature of Ti alloys from ~650ºC to 800-900ºC without excessive scale spallation.

Cr 3 C 2 -NiCr, NiCr, WC-Co and Stellite-6 alloy coatings were sprayed on ASTM SA213-T11 steel using the HVOF process. Liquid petroleum gas (LPG) was used as the fuel gas. Hot corrosion studies were conducted on the uncoated as well as HVOF sprayed specimens after exposure to molten salt at 9000C under cyclic conditions. The thermo-gravimetric technique was used to establish the kinetics of corrosion. XRD, SEM/EDAX and EPMA techniques were used to analyse the corrosion products. All these overlay coatings showed a better resistance to hot corrosion as compared to that of uncoated steel. NiCr Coating was found to be most protective followed by the Cr 3 C 2 -NiCr coating. WC-Co coating was least effective to protect the substrate steel. It is concluded that the formation of Cr 2 O 3 , NiO, NiCr 2 O 4 , and CoO in the coatings may contribute to the development of a better hot corrosion resistance. The uncoated steel suffered corrosion in the form of intense spalling and peeling of the scale, which may be due to the formation of unprotective Fe 2 O 3 oxide scale.

The goal of this work is to develop a flame sprayed NiCr-Cr 3 C 2 coating that resists oxidation, corrosion, and erosion in boiler environments and to assess the influence of Cr 3 C 2 fraction and sealing on coating performance. In the experiments, NiCr cermet alloys with different proportions of chromium carbide were applied to boiler steel substrates by means of subsonic velocity flame spraying and some of the coatings were sealed with a silicon resin. The paper describes the various tests performed and presents the results. Paper includes a German-language abstract.

In this study, high velocity-oxy fuel (HVOF) technique was used to deposit Cr 3 C 2 -NiCr coating on the Ni-base superalloys for their hot corrosion applications. The coatings were characterised with regard to coating thickness, porosity, microhardness and microstructure. The hot corrosion behaviours of the bare and Cr 3 C 2 -NiCr coated superalloys were studied after exposure to molten salt (Na 2 SO 4 -60%V 2 O 5 ) at 900°C under cyclic conditions. Optical microscopy, XRD, SEM/EDAX and EPMA techniques were used to characterise the coatings. The thermogravimetric technique was used to establish kinetics of corrosion. The structure of the as sprayed Cr 3 C 2 -NiCr coating mainly consisted of γ-nickel solid solution with very low intensity peaks of Cr 7 C 3 and Cr 2 O 3 phases. Some porosity (less than 1.5%), inclusions, unmelted and semi-melted powder particles were observed in the structure of the coatings. Coating microhardness values were found to be in the range of 850-900 Hv (Vickers hardness). The Cr 3 C 2 - NiCr coating was resistant to hot corrosion in the given molten salt environment at 900°C. The hot corrosion resistance imparted by Cr 3 C 2 -NiCr coatings may be attributed to the formation of oxides of nickel, chromium, and spinels of nickel and chromium.

Nickel-chromium alloys have been used as coatings to deal with oxidation environments at high temperature. The present work is a comparative study of HVOF and cold sprayed Ni-20Cr coating on a boiler steel (SAE 213-T22) in a molten salt environment of Na 2 SO 4 -60%V 2 O 5 at 900°C under cyclic conditions. The weight change technique was used to establish the kinetics of corrosion. X-ray diffraction, surface and cross-sectional FE-SEM/EDS techniques were used to analyse the corrosion products. The hot corrosion resistance of both the coatings was better than the uncoated steel. This may be attributed to the formation of oxides and spinels of nickel and chromium in the coated steels. These oxides might have blocked the pores and splat boundaries, and acted as diffusion barriers to the inward diffusion of corroding species. Based upon the overall results and subsequent analysis of hot-corrosion data the cold spray process may be recommended as a better choice for the deposition of the Ni-20Cr coating on Mo-containing T22 steel in comparison with the HVOF spray process for hot corrosion protection.

This paper evaluates the effect of bond coat oxidation on the coating life of graded, duplex, and triplex TBC systems deposited on Inconel 617 and 738 substrates by vacuum plasma spraying. In oxidation experiments, the triplex system had the lowest number of cycles to failure. The graded system was found to be superior to the duplex system in terms of oxidation resistance, but inferior in terms of hot corrosion resistance. It was also found that the various TBC systems are more durable on Inconel 738 than on Inconel 617, particularly the graded systems. Paper includes a German-language abstract.

Zirconia based, 8Y 2 O 3 -ZrO 2 and 22MgO-ZrO 2 thick thermal barrier coatings (1000µm), were studied with different sealing methods for diesel engine applications. Aim of the sealing procedure was to improve hot corrosion resistance and mechanical properties of porous TBC coatings. The surface of the TTBCs was sealed with two different methods, phosphate based sealing treatment and laser glazing. The thickness of the densified top layer in all cases was 50-400µm. XRD analysis showed some minor phase changes and reaction products caused by phosphate based sealing treatment and some crystal orientation changes and phase changes in laser-glazed coatings. The porosity of the outer layer of the sealed coating decreased in all cases, which led to increased microhardness values. The hot corrosion resistance of TTBCs against 60Na 2 SO 4 - 40V 2 O 5 deposit was determined in isothermal exposure at 650°C for 200 h. Corrosion products and phase changes were studied with XRD after the test. Short-term engine test was performed for the reference coatings (8Y 2 O 3 - ZrO 2 and 22MgO-ZrO 2 ) and for the phophate sealed coatings. Engine tests were performed at the maximum load of the engine and it was aimed to evaluate the thermal cycling resistance of the sealed coatings. All the coatings passed the engine test, but some vertical cracks were detected in the phosphate sealed coatings.

Due to the aggressive operation conditions of turbine hot sections, protective coatings are required to provide oxidation and hot corrosion resistance for superalloy components. Thermal barrier coatings (TBCs) are comprised of a ceramic top coat and a metallic bond coat (BC) and are typically used as thermal protection systems against these aggressive environments. Conventional BC materials are MCrAlX, with M being metals or alloys (e.g., Ni, Co or NiCo) and X being reactive elements such as Y, Hf, Ta, Si. Due to their strength, thermal stability, and oxidation resistance, high-entropy alloys (HEAs) have presented promise for use as BC materials in hightemperature applications. Owing to its cocktail effect, optimally chosen HEAs could help to enhance the hot corrosion resistance of BCs by forming a more continuous, dense, and uniform thermally grown oxide (TGO). Furthermore, HEAs could help to control the diffusion between the bonding layer and substrate in elevated temperature environments. This paper will discuss the thermodynamic, mechanical, and microstructural behaviour of HEAs. Furthermore, the selection and usage of HEAs as BCs will be explored and compared to conventional BCs in TBC systems.

A series of Ni-based cored wires with different boron contents were designed to prepare corrosion-resistant coatings by two-roll wire-arc spraying. These coatings were evaluated for their potential to provide added protection and reduced maintenance for applications in waste-to-energy (WTE) plants. The as-deposited coatings, which primarily are composed of nanocrystalline particles, exhibit uniform and dense layered structures with porosity of about 3%. The investigators selected thermo-gravimetric techniques to evaluate the high-temperature corrosion behavior of the coatings in molten salt environment (Na 2 SO 4 -10 wt% NaCl) at 800°C. The coated surfaces exhibited significantly reduced corrosion rates in comparison to those of the SA 213-T 2 substrate during all tests. These results were due to the formation in the coatings of composite surface oxide films, including Cr 2 O 3 and NiCr 2 O 4 , which serve to prevent the diffusion or penetration of corrosive species. Furthermore, the boron content appears to have a significant influence on the corrosion behavior of the designed coatings: the coating with the best performance had 16 at. % B added. The wire-arc sprayed Ni-based coatings could be an effective and economical treatment to prevent corrosion and extend the lifetime of super-heater tubes in WTE plants.

In gas turbines and diesel engines there is a demand for Thick Thermal Barrier Coatings (TTBCs), because of the increased process combustion temperatures. Unfortunately the increased thickness of plasma sprayed TBCs normally leads to a reduced coating lifetime. So for that reason the coating structures have to be modified. When modifying the structure of TTBCs, the focus is normally set on elastic modulus reduction of the thick coating, in order to improve the coating strain tolerance. On the other hand, coating structural modification procedures, such as sealing treatments, can be performed when increased hot corrosion resistance or better mechanical properties are needed. In this paper we introduced several modified zirconia based TTBC structures and their specific microstructural properties. Coating surface sealing procedures such as phosphate sealing, laser-glazing and sol-gel impregnation were studied as potential methods in increasing the hot corrosion and erosion resistance of TTBCs. Some microstructural modifications were also made by introducing segmentation cracks into the coating structures by laserglazing and by using special spraying parameters. These last two methods were studied in order to increase the strain tolerance of TTBCs. The coating microstructures were characterized by optical microscopy, SEM, TEM, EDS analysis and X-ray diffraction. The effect of sealing procedures was studied on basic thermal and mechanical properties of the coatings. In the paper it was also presented some correlations between the coating properties and microstructures, and discussed about the advantages and drawbacks of each modification procedure.

This work investigates the high-temperature oxidation kinetics of CoCrAlSiY coatings with different Si concentrations. Hot-corrosion resistance is determined at 800 and 900 °C via hot salt coating, thermal shock resistance is measured at 1050 °C, and the oxidation and corrosion products are analyzed through mineralogical and micro analysis. The results show that Si promotes the formation of an Al 2 O 3 film that improves oxidation and corrosion resistance, but excessive amounts reduce thermal shock resistance.

In this investigation, Ni-20Cr alloy powder was deposited on SA 516 boiler steel by cold spraying. The oxidation kinetics of both coated and uncoated samples, evaluated in molten salt, followed a parabolic rate. The rate constant of the Ni-20Cr coated steel was much lower than that of the bare boiler steel. X-ray diffraction, SEM-EDX, and X-ray mapping were used to analyze the oxidation products of the coated and uncoated boiler steel. The uncoated steel exhibited intense spalling and peeling of its oxide scale, which may be due to the formation of Fe 2 O 3 oxides. The Ni-20Cr coating reduced the weight gain of the steel by more than 87% possibly due to the formation of nickel and chromium oxides.

Cr 3 C 2 -25%NiCr, Stellite 6, NiCrBSi and Hastelloy C-276 coatings were deposited on substrate material P91 by HP/HVOF (High Pressure / High Velocity Oxygen Fuel) thermal spraying technology. The resistance against high temperature corrosion was evaluated exposition of coatings to corrosive-aggressive environment in the form of molten salts mixture with composition of 60% V 2 O 5 and 40% Na 2 SO 4 at temperature of 750 °C. Further, coatings were exposed to cyclic conditions. After the corrosion tests, all coatings were analyzed using scanning electron microscope (SEM), and analysis of elemental composition (EDX). Alloys-based coatings showed very similar corrosion mechanism in the selected aggressive environment and the same can be stated about cermet coatings. The obtained results prove that HVOF deposited coatings can replace current surface protection of components in power equipment such as nitriding.

In this study, two coatings, one produced by HVOF spraying, the other by physical vapor deposition (PVD), were applied on a nickel superalloy substrate in order to compare their hot corrosion behavior. The coating samples were initially characterized by OM and SEM-EDS analysis, then a mixture of V 2 O 5 , Na 2 SO 4 , and NaCl was deposited on the surface and the samples were to 900 °C for 35 h. The results show that the PVD CrN coating provided better corrosion protection than HVOF-sprayed CrC-NiCrAlY.