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Microstructural analysis and hot corrosion behavior of HVOF-sprayed Ni-22Cr-10Al-1Y and Ni-22Cr-10Al-1Y-SiC (N) coatings on ASTM-SA213-T22 steel

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Abstract

The present paper deals with the investigation of microstructure and high-temperature hot corrosion behavior of high-velocity oxy fuel (HVOF)-produced coatings. Two powder coating compositions, namely, Ni22Cr10Al1Y alloy powder and Ni22Cr10Al1Y (80wt%; microsized)-silicon carbide (SiC) (20wt%; nano (N)) powder, were deposited on a T-22 boiler tube steel. The hot corrosion behavior of bare and coated steels was tested at 900°C for 50 cycles in Na2SO4-60wt%V2O5 molten-salt environment. The kinetics of corrosion was established with weight change measurements after each cycle. The microporosity and microhardness of the as-coated samples have been reported. The X-ray diffraction, field emission-scanning electron microscopy/energy dispersive spectroscopy, and X-ray mapping characterization techniques have been utilized for structural analysis of the as-coated and hot-corroded samples. The results showed that both coatings were deposited with a porosity less than 2%. Both coated samples revealed the development of harder surfaces than the substrate. During hot corrosion testing, the bare T22 steel showed an accelerated corrosion in comparison with its coated counterparts. The HVOF-sprayed coatings were befitted effectively by maintaining their adherence during testing. The Ni22Cr10Al1Y-20wt%SiC (N) composite coating was more effective than the Ni-22Cr-10Al-1Y coating against corrosion in the high-temperature fluxing process.

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Acknowledgements

The authors thankfully acknowledge IKGPTU, Jalandhar (Punjab) for their help in carrying out this experimental research. The authors also appreciatively acknowledge DST, New Delhi for their research grant (No. SB/FTP/ETA-435/2012, Dated-10/6/2013) that funded the research and development of the project entitled “Nano-composite Coatings to Control Erosion of Boiler Tubes of Steam Generating Plants.”

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Authors and Affiliations

  1. Department of Mechanical Engineering, IKGPTU, Jalandhar, Punjab, 144603, India

    Gurmail Singh & Vikas Chawla

  2. Department of Aerospace Engineering, Chandigarh University, Gharuan, Punjab, 140413, India

    Gurmail Singh

  3. Department of Mechanical Engineering, BBSBEC, Fatehgarh Sahib, 140407, Punjab, India

    Niraj Bala

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  1. Gurmail Singh
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Singh, G., Bala, N. & Chawla, V. Microstructural analysis and hot corrosion behavior of HVOF-sprayed Ni-22Cr-10Al-1Y and Ni-22Cr-10Al-1Y-SiC (N) coatings on ASTM-SA213-T22 steel. Int J Miner Metall Mater 27, 401–416 (2020). https://doi.org/10.1007/s12613-019-1946-y

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