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High Temperature Corrosion Behavior of Cold Spray Ni-20Cr Coating on Boiler Steel in Molten Salt Environment at 900 °C

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Abstract

Cold spray is an emerging technology that produces high density metallic coatings with low oxide contents and high thermal conductivity, which makes them ideal for high temperature corrosion resistance. In the current investigation, Ni-20Cr alloy powder was deposited on SA 516 boiler steel (0.19C-1.07Mn-0.020S-0.25P-0.010Si-balance Fe) by cold spray process. Oxidation kinetics was established for the uncoated and cold spray Ni-20Cr coated boiler steel in an aggressive environment of Na2SO4-60%V2O5 at 900 °C for 50 cycles by the weight change technique. X-ray diffraction, FE-SEM/EDAX, and x-ray mapping techniques were used to analyze the oxidation products. Uncoated steel suffered corrosion in the form of intense spalling and peeling of its oxide scale, which may be due to the formation of unprotective Fe2O3 oxides. The Ni-20Cr coating was successful in reducing the weight gain of the steel by 87.2% which may be due to the formation of oxides of nickel and chromium.

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Acknowledgments

Harpreet Singh et al. thankfully acknowledge the research Grant from Council of Scientific and Industrial Research, New Delhi (File No. 22(0441)/07/EMR-II, dated October 23, 2007) for carrying out the R & D work on “Investigations on the role of cold spray coatings to control hot corrosion of steam generating plants.” The authors express their sincere thanks to ASB Industries, Inc., Barbeton, Ohio, USA and Guru Gobind Singh Super Thermal Power Plant, Ropar (India) for their kind co-operation during this work.

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Authors and Affiliations

  1. Baba Banda Singh Bahadur Engineering College, Fatehgarh Sahib, Punjab, India

    Niraj Bala

  2. Indian Institute of Technology Ropar, Rupnagar, Punjab, India

    Harpreet Singh

  3. Indian Institute of Technology, Roorkee, Uttrakhand, India

    Satya Prakash

Authors
  1. Niraj Bala
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  2. Harpreet Singh
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  3. Satya Prakash
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Correspondence to Niraj Bala.

Additional information

This article is an invited paper selected from presentations at the 2009 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Expanding Thermal Spray Performance to New Markets and Applications: Proceedings of the 2009 International Thermal Spray Conference, Las Vegas, Nevada, USA, May 4-7, 2009, Basil R. Marple, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, OH, 2009.

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Bala, N., Singh, H. & Prakash, S. High Temperature Corrosion Behavior of Cold Spray Ni-20Cr Coating on Boiler Steel in Molten Salt Environment at 900 °C. J Therm Spray Tech 19, 110–118 (2010). https://doi.org/10.1007/s11666-009-9437-8

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  • DOI: https://doi.org/10.1007/s11666-009-9437-8

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