Comparative hot corrosion performance of APS and Detonation sprayed CoCrAlY, NiCoCrAlY and NiCr coatings on T91 boiler steel

•DSC coatings offered better hot corrosion resistance than the APS coatings.•NiCr composition provides excellent corrosion resistance under molten salt enviorment.•Chromia and spinel oxides resisted hot corrosion ingress in coatings.•Lack of SO2 caused lower stability of Alkali iron trisulphates and...

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Published inCorrosion science Vol. 189; p. 109556
Main Authors C., Sundaresan, B., Rajasekaran, S., Varalakshmi, K., Santhy, Rao, D. Srinivasa, G., Sivakumar
Format Journal Article
LanguageEnglish
Published Amsterdam Elsevier Ltd 15.08.2021
Elsevier BV
Subjects
A. Cobalt
A. Metal coatings
A. Nickel
Aluminum oxide
B. SEM
B. XRD
C. Hot corrosion
Chromium oxides
Corrosion resistance
Corrosion resistant steels
Detonation
Heat resistant steels
Hot corrosion
Martensitic stainless steels
Potassium sulfate
Protective coatings
Salt deposits
A. Nickel
B. SEM
B. XRD
A. Metal coatings
A. Cobalt
C. Hot corrosion
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Abstract •DSC coatings offered better hot corrosion resistance than the APS coatings.•NiCr composition provides excellent corrosion resistance under molten salt enviorment.•Chromia and spinel oxides resisted hot corrosion ingress in coatings.•Lack of SO2 caused lower stability of Alkali iron trisulphates and primarily oxidation attack.•DFT analysis performed to validate the thermodynamic stability of oxides formed. Hot corrosion performance of Atmospheric Plasma Spray (APS) and Detonation spray (DSC) CoCrAlY, NiCoCrAlY, and NiCr coatings on T91 steel were investigated at 650 °C for 100 cycles under Na2SO4-K2SO4-Fe2O3 mixed salt deposit in ambient air. The hot corrosion resistance of DSC coatings was found to be superior to their APS counterparts. Chromia and spinel oxides provided excellent corrosion resistance while no α-Al2O3 was observed. DSC NiCr and APS NiCoCrAlY offered the most and the least corrosion resistance, respectively. DFT calculation was performed to validate the thermodynamic stability of each oxide and identify the precise oxide formation.
AbstractList Hot corrosion performance of Atmospheric Plasma Spray (APS) and Detonation spray (DSC) CoCrAlY, NiCoCrAlY, and NiCr coatings on T91 steel were investigated at 650 °C for 100 cycles under Na2SO4-K2SO4-Fe2O3 mixed salt deposit in ambient air. The hot corrosion resistance of DSC coatings was found to be superior to their APS counterparts. Chromia and spinel oxides provided excellent corrosion resistance while no α-Al2O3 was observed. DSC NiCr and APS NiCoCrAlY offered the most and the least corrosion resistance, respectively. DFT calculation was performed to validate the thermodynamic stability of each oxide and identify the precise oxide formation.
•DSC coatings offered better hot corrosion resistance than the APS coatings.•NiCr composition provides excellent corrosion resistance under molten salt enviorment.•Chromia and spinel oxides resisted hot corrosion ingress in coatings.•Lack of SO2 caused lower stability of Alkali iron trisulphates and primarily oxidation attack.•DFT analysis performed to validate the thermodynamic stability of oxides formed. Hot corrosion performance of Atmospheric Plasma Spray (APS) and Detonation spray (DSC) CoCrAlY, NiCoCrAlY, and NiCr coatings on T91 steel were investigated at 650 °C for 100 cycles under Na2SO4-K2SO4-Fe2O3 mixed salt deposit in ambient air. The hot corrosion resistance of DSC coatings was found to be superior to their APS counterparts. Chromia and spinel oxides provided excellent corrosion resistance while no α-Al2O3 was observed. DSC NiCr and APS NiCoCrAlY offered the most and the least corrosion resistance, respectively. DFT calculation was performed to validate the thermodynamic stability of each oxide and identify the precise oxide formation.
ArticleNumber 109556
Author G., Sivakumar
Rao, D. Srinivasa
C., Sundaresan
B., Rajasekaran
K., Santhy
S., Varalakshmi
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  givenname: Rajasekaran
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  surname: B.
  fullname: B., Rajasekaran
  email: b.rajasekaran@nitk.edu.in
  organization: Department of Metallurgical and Materials Engineering, National Institute of Technology, Karnataka (NITK), 575025, Surathkal, India
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  givenname: Varalakshmi
  surname: S.
  fullname: S., Varalakshmi
  organization: Department of Metallurgical and Materials Engineering, National Institute of Technology, Karnataka (NITK), 575025, Surathkal, India
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Snippet •DSC coatings offered better hot corrosion resistance than the APS coatings.•NiCr composition provides excellent corrosion resistance under molten salt...
Hot corrosion performance of Atmospheric Plasma Spray (APS) and Detonation spray (DSC) CoCrAlY, NiCoCrAlY, and NiCr coatings on T91 steel were investigated at...
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StartPage 109556
SubjectTerms A. Cobalt
A. Metal coatings
A. Nickel
Aluminum oxide
B. SEM
B. XRD
C. Hot corrosion
Chromium oxides
Corrosion resistance
Corrosion resistant steels
Detonation
Heat resistant steels
Hot corrosion
Martensitic stainless steels
Potassium sulfate
Protective coatings
Salt deposits
Title Comparative hot corrosion performance of APS and Detonation sprayed CoCrAlY, NiCoCrAlY and NiCr coatings on T91 boiler steel
URI https://dx.doi.org/10.1016/j.corsci.2021.109556
https://www.proquest.com/docview/2561103483
Volume 189
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