The hot corrosion behavior of plasma sprayed zirconia coatings stabilized with yttria, ceria, and titania in sodium sulfate and vanadium oxide

Habibi, M. H.; Guo, Shengmin

doi:10.1002/maco.201307331

Cited by 30 publications

(10 citation statements)

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“…Fe gets oxidized in the presence of O to form Fe 2 O 3 oxide layer. Habibi and Guo (2015) and Katiki et al (2014) also observed similar outcomes at elevated temperature in the molten salt environment.…”

Section: Discussionmentioning

confidence: 62%

Hot corrosion behaviour of CNT-reinforced ZrO₂-Y₂O₃ composite coatings on boiler tube steel at 900°C

Kumar

Bhatia²,

Singh³

2021

ACMM

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Purpose In Indian thermal power plants, the main cause of boiler tube failure is the presence of molten sulphates and vanadates, which deteriorate the tube material at high temperatures. To combat the hot corrosion failure of metals, thermal spray technology is adopted. This study aims to investigate and study the effect of hot corrosion behaviour of carbon nanotube (CNT)-reinforced ZrO2-Y2O3 composite coatings on T-91 boiler tube steel in a molten salt environment at 900 °C for 50 cycles. Design/methodology/approach A plasma spray technique was used for development of the coatings. The samples were exposed to hot corrosion in a silicon tube furnace at 900 °C for 50 cycles. After testing, the test coupons were analysed by X-ray diffraction, scanning electron microscopy/energy dispersive spectroscopy and cross-sectional analysis techniques to aid understanding the kinetics of the corrosion reaction. Findings CNT-based reinforced coatings showed lower weight gain along with the formation of protective oxide scales during the experimentation. Improvement in protection against hot corrosion was observed with increase in CNT content in the coating matrix. Originality/value It is pertinent to mention here that the high temperature behaviour of CNT-reinforced ZrO2-Y2O3 composite on T-91 steel at 900°C temperature in molten salt environment has never been studied. Thus, the present research was conducted to provide useful results for the application of CNT-reinforced composite coatings at elevated temperature.

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Section: Discussionmentioning

confidence: 62%

Hot corrosion behaviour of CNT-reinforced ZrO₂-Y₂O₃ composite coatings on boiler tube steel at 900°C

Kumar

Bhatia²,

Singh³

2021

ACMM

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“…Its unique crystal structure also allows for the formation of epitaxial thin films, which can further enhance its performance as a TBC material. The use of LaAlO 3 in TBCs has shown promising results, with improved thermal barrier performance and increased durability under hightemperature and thermal cycling conditions [61].…”

Section: Lanthanum Aluminate (Laalo 3 )mentioning

confidence: 99%

Recent Development in Advance Ceramic Materials and Understanding the Mechanisms of Thermal Barrier Coatings Degradation

Iqbal

Moskal

2023

Arch Computat Methods Eng

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Metallic alloys' behavior at high temperatures, especially their response to corrosion and formation of protective surface layers, has long been a focus of scientific inquiry. Although certain alloy compositions require an initiation period before hot corrosion advances to the propagation stage, no combination of alloys can be considered impervious to hot corrosion indefinitely. The capacity of nickel-based materials to tolerate extreme circumstances such high temperatures, acidity, corrosion, and scratching is highly valued. However, they are unable to satisfy the strict demands of today's high-temperature applications. The durability of thermal barrier coatings (TBCs), which are prone to oxidation, rust, and degradation from sulphates and foreign object damage, has been the subject of recent study. For sophisticated ceramic materials exposed to high temperatures, hot rust degradation poses a considerable challenge. The main objective of this study is to investigate the effects of severe degradation on several advanced ceramic material types and their level of advancement. The purpose of the inquiry is to comprehend the deteriorating processes at the long term working condition, including the function of oxidation and liquid salts. Additionally, we investigate the effects of temperature, environment, and contact duration on the heated weathering behavior of earthenware. Finally, we discuss strategies for mitigating hot corrosion degradation in ceramics, such as protective coatings like new design of TBCs, doping, and composition optimization. This paper aims to offer a thorough understanding of the hot corrosion behavior of ceramics, which is crucial for developing durable materials suitable for high-temperature applications. Additionally, it explores the fabrication of protective coatings and addresses the challenges faced in this regard. The insights gained from this research can contribute to the advancement of resilient ceramic fabrics and the development of effective protective coatings.

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“…The tests reported in the literature have been conducted from 700 o C to about 1050 o C using different salt concentrations, with a majority of the tests focused on YSZ thermal barrier coatings. Limited research on the corrosion mechanism of other top coat materials such as gadolinium zirconate [48,49,55], ceria-stabilized zirconia [56][57][58], titaniastabilized zirconia [58], scandia and yttria co-stabilized zirconia [59] and zirconia-alumina [54] have been reported as well.…”

Section: Hot Corrosion Tests -Failure Mechanismsmentioning

confidence: 99%

Failure mechanisms in APS and SPS thermal barrier coatings during cyclic oxidation and hot corrosion

Jonnalagadda¹

2017

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Linköping 2017Front page image: The top view of yttria stabilized zirconia thermal barrier coating after exposure to a salt mixture of vanadium pentoxide and sodium sulfate at 900 o C.During the course of research underlying this thesis, Krishna Praveen Jonnalagadda was enrolled in Agora Materiae, a multidisciplinary doctoral program at Linköping University, Sweden.ISBN: 978-91-7685-594-2 ISSN: 0280-7971Printed by LiU-Tryck 2017 iii AbstractThermal Barrier Coatings (TBCs) are advanced material systems that are being used in the hot sections of gas turbines such as combustor, turbine blades, and vanes. The top ceramic coating in TBCs provides insulation against the hot gases and the intermediate metallic bond coat provides oxidation and corrosion resistance to the underlying turbine components.Durability of thermal barrier coatings is very important for the overall performance of the gas turbine. TBCs can fail in several different ways and there is a combination of more than one failure mechanism in most situations. One of the most widely used TBC is atmospheric plasma sprayed (APS) yttria stabilized zirconia (YSZ). Both the deposition technique and the TBC material have certain limitations. The main aim of this research is to study new TBC materials and/or new deposition techniques and compare with the conventional YSZ and understand their failure mechanisms during cyclic oxidation and hot corrosion.Thermal cyclic oxidation of a newly developed high purity nano YSZ thermal barrier coating has been studied. Cross sectional analysis of exposed as well as completely failed samples showed a mixed-type failure caused by crack propagation parallel to the bond coat/top coat interface. The majority of the damage occurred towards the end of the coating life. A finite element model has been developed to study the probability of crack growth along different paths that leads to the final failure.Hot corrosion mechanism in suspension plasma sprayed two-layer gadolinium zirconate/YSZ, three-layer dense gadolinium zirconate/gadolinium zirconate/YSZ, and a single-layer YSZ has been studied in the presence of sodium sulfate and vanadium pentoxide. The test results showed that gadolinium zirconate coatings were more susceptible to corrosion compared to YSZ coatings despite gadolinium zirconate coatings having lower reactivity with the corrosive salts.Thermal cycling behavior of a high chromium bond coat has been studied. Cross-sectional analysis showed formation of sandwich type microstructure with chromium rich oxide and alumina as the top and the bottom layers.Inter-diffusion of minor elements between different MCrAlY coatings -substrate systems has been studied using, diffusion simulation software, DICTRA. The simulation results showed that the diffusion of minor elements in the coatings is dependent on the rate of β phase depletion in the beginning. After the depletion of β phase there was no clear dependence of the coating composition on the diffusion of minor elements.v SammanfattningTermiska barriärskikt, eller TBC från...

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The hot corrosion behavior of plasma sprayed zirconia coatings stabilized with yttria, ceria, and titania in sodium sulfate and vanadium oxide

Cited by 30 publications

References 40 publications

Hot corrosion behaviour of CNT-reinforced ZrO₂-Y₂O₃ composite coatings on boiler tube steel at 900°C

Hot corrosion behaviour of CNT-reinforced ZrO₂-Y₂O₃ composite coatings on boiler tube steel at 900°C

Recent Development in Advance Ceramic Materials and Understanding the Mechanisms of Thermal Barrier Coatings Degradation

Failure mechanisms in APS and SPS thermal barrier coatings during cyclic oxidation and hot corrosion

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The hot corrosion behavior of plasma sprayed zirconia coatings stabilized with yttria, ceria, and titania in sodium sulfate and vanadium oxide

Cited by 30 publications

References 40 publications

Hot corrosion behaviour of CNT-reinforced ZrO2-Y2O3 composite coatings on boiler tube steel at 900°C

Hot corrosion behaviour of CNT-reinforced ZrO2-Y2O3 composite coatings on boiler tube steel at 900°C

Recent Development in Advance Ceramic Materials and Understanding the Mechanisms of Thermal Barrier Coatings Degradation

Failure mechanisms in APS and SPS thermal barrier coatings during cyclic oxidation and hot corrosion

Contact Info

Product

Resources

About

Hot corrosion behaviour of CNT-reinforced ZrO₂-Y₂O₃ composite coatings on boiler tube steel at 900°C

Hot corrosion behaviour of CNT-reinforced ZrO₂-Y₂O₃ composite coatings on boiler tube steel at 900°C