Microstructure and Corrosion Resistance of NiCr-Based Coatings in Simulated Coal-Fired Boiler Conditions

Fu, Caixia; Li, Y.; Wang, Y. F.

doi:10.1007/s11085-020-10016-5

Cited by 8 publications

(4 citation statements)

References 75 publications

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“…Yet, the material selection for the boiler and heat exchanger applications is influenced mainly by the cost of the materials and ease of fabrication. [ 10 ] Applying coatings or overlay materials on the components will offer protection against corrosion under elevated conditions. Superalloys are materials resistant to heat, corrosion and oxidation and are used mainly on sensitive parts exposed to severe operating conditions.…”

Section: Introductionmentioning

confidence: 99%

“…The metallurgical bond between the substrate metal and the overlay material should be strong enough as it will eliminate the diffusion of the corrosive elements at the interface region. [10] The components of dissimilar metals with different properties are prone to failure when experiencing a large temperature gradient. [17,18] Ni-Cr, Hastelloy (C276), and Inconel 718 HVOF coatings (micro and nanostructured) were deposited on the AISI 304 substrate, and the hot corrosion and hot oxidation studies were conducted at 900°C on the molten salt (Na 2 SO 4 + 60% V 2 O 5 ) environment.…”

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confidence: 99%

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High temperature corrosion performance of Inconel 625 hard overlays deposited on stainless steel substrate

Nachimuthu,

Gosipathala,

Arasappan

et al. 2024

Materials & Corrosion

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In elevated conditions, austenitic stainless steels suffer intense damage by corrosion because of the severe oxide scale development. Giving stainless steel a corrosion‐resistant surface coating can prevent excessive damage. In this case, welding‐based overlaying is a potential method to restore the damaged parts as it has a higher productivity rate. This investigation articulates the corrosion resistance behavior of the multiple overlapped Inconel 625 (IN625) weld overlays on the AISI 316L substrate plate. The corrosion resistance at elevated temperatures was investigated with kinetic curves, further revealing the corrosion products from the sample surface. Characterization techniques like scanning electron microscopy with energy‐dispersive spectroscopy, X‐ray diffraction, and Raman spectroscopy were employed to analyze the corrosion products. Hot corrosion kinetics in the molten salt environment (Na2SO4 + V2O5) revealed that the IN625 overlay samples gained a weight of 40.15 mg/cm2, and the substrate had a weight gain of 65.42 mg/cm2. From the hot oxidation kinetics, it is evident that the mass gained by the substrate is more than twice that of the Inconel overlay sample. Furthermore, the formation of oxides and spinel phases rich in nickel (NiO, NiCr2O4) highly influenced the corrosion kinetics of the multiple overlapped IN625 overlay sample. The AISI 316L substrate sample revealed the existence of critical oxide phases such as Fe2O3 and Cr2O3, which were lesser and did not influence the corrosion resistance at 900°C. In the present investigation, the multiple overlapped IN625 weld overlay offered excellent corrosion resistance at high temperature compared to the AISI 316L.

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Section: Introductionmentioning

confidence: 99%

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confidence: 99%

High temperature corrosion performance of Inconel 625 hard overlays deposited on stainless steel substrate

Nachimuthu,

Gosipathala,

Arasappan

et al. 2024

Materials & Corrosion

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“…To overcome cost issue Ni-Cr based thermal spray coatings were often advised for components operating at high temperatures. However, as a result of iron element diffusion into coated coatings, their performance degrades when service temperatures above 650 °C were recorded [11][12][13]. Therefore, to match industry standards, it is necessary to create efficient coating solutions [14].…”

Section: Introductionmentioning

confidence: 99%

High-temperature erosion behavior of Al₂O₃ reinforced Inconel625 high velocity oxy-fuel sprayed and direct-aged composite coatings

Prashar,

Vasudev

2024

Phys. Scr.

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In this study, Inconel625+30%Al2O3 (IN30AL) blended powders were sprayed on a commercially used boiler steel ASTM SA210 GrA1 using high-velocity oxy-fuel approach (HVOF). The microstructure, mechanical properties and elevated temperature erosion behavior of post-processed coatings and as-sprayed IN30ALcoatings were investigated. The elevated temperature erosion studies on IN30AL coatings both as-sprayed and post-processed were investigated at 900 °C temperature at two impact angles 30° and 90° using standard high temperature erosion test rig. Phase composition, interface of substrate/coating, and morphologies of eroded coatings were examined using x-ray diffraction, x-ray maps, scanning electron microscope, & energy dispersive spectrometer techniques. Compared with the as-sprayed IN30AL coatings, the heat-treated coatings have refined microstructure, better mechanical properties which improve the elevated temperature erosion resistance of IN30ALcoatings.

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“…NiCr-based coatings protect TP347 from hot corrosion in a 650 °C flue gas environment. The S-induced corrosion study revealed that 45CT coating achieved exceptional corrosion resistance through protective Cr 2 O 3 scales, whereas NiCrBSi suffered severe corrosion due to sulfur [1]. The electrochemical method was used to study the corrosion of laser-cladded Inconel 625 on S235JR steel.…”

Section: Introductionmentioning

confidence: 99%

Comparative investigation of surface modification and corrosion behaviour on SS304 and SS316 Coated with Inconel 625 in Air and Molten Salt Environment

Sundaram¹,

Singaravelu²,

Vikneswaran³

2022

Surf. Topogr.: Metrol. Prop.

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The high operating temperature-based industry extensively requires coating of material surfaces that are subjected to a high-temperature environment to improve their surface and resistance to corrosion. The current study investigated the surface modification and corrosion behaviour of Inconel 625-coated SS304 and SS316 materials in an air and molten salt environment at 800 °C. The plasma spray method was used to coat the Inconel 625 powder over the substrates. Techniques like quantitative weight gain/loss method, surface roughness, hardness measurement, and characterization through microstructure analysis were used to characterize and analyze the corrosion behaviour and microstructure of Inconel coated SS. It was observed that the coat had a noticeably layered structure with layers parallel to the surface of the substrate. The experimental results revealed that the uncoated SS suffered corrosion in the form of residue and peeling up of its oxide scale. Whereas the surface of the IN625-coated SS showed excellent resistance to corrosion formation. It was found that the coating lowered the mass gain of the SS316 by 65% when compared to uncoated SS.

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Microstructure and Corrosion Resistance of NiCr-Based Coatings in Simulated Coal-Fired Boiler Conditions

Cited by 8 publications

References 75 publications

High temperature corrosion performance of Inconel 625 hard overlays deposited on stainless steel substrate

High temperature corrosion performance of Inconel 625 hard overlays deposited on stainless steel substrate

High-temperature erosion behavior of Al₂O₃ reinforced Inconel625 high velocity oxy-fuel sprayed and direct-aged composite coatings

Comparative investigation of surface modification and corrosion behaviour on SS304 and SS316 Coated with Inconel 625 in Air and Molten Salt Environment

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Microstructure and Corrosion Resistance of NiCr-Based Coatings in Simulated Coal-Fired Boiler Conditions

Cited by 8 publications

References 75 publications

High temperature corrosion performance of Inconel 625 hard overlays deposited on stainless steel substrate

High temperature corrosion performance of Inconel 625 hard overlays deposited on stainless steel substrate

High-temperature erosion behavior of Al2O3 reinforced Inconel625 high velocity oxy-fuel sprayed and direct-aged composite coatings

Comparative investigation of surface modification and corrosion behaviour on SS304 and SS316 Coated with Inconel 625 in Air and Molten Salt Environment

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High-temperature erosion behavior of Al₂O₃ reinforced Inconel625 high velocity oxy-fuel sprayed and direct-aged composite coatings