Oxidation behavior of Wc-12Co and Cr3C2-25NiCr sprayed on ASTM A213 T91 steel using a D-gun

Arminder Singh Walia; Nalin Somani; Nitin Kumar Gupta; Anshuman Das

doi:10.3989/revmetalm.e256.1691

Authors

Arminder Singh Walia Mechanical Engineering Department, Thapar Polytechnic College https://orcid.org/0000-0002-7692-5507
Nalin Somani Department of Mechanical Engineering, DIT University Dehradun https://orcid.org/0000-0002-3239-2534
Nitin Kumar Gupta Department of Mechanical Engineering, DIT University Dehradun https://orcid.org/0000-0002-0140-8206
Anshuman Das School of Mechanical Engineering, VIT Chennai https://orcid.org/0000-0001-9644-7074

DOI:

https://doi.org/10.3989/revmetalm.e256.1691

Keywords:

Boiler Steel, Detonation gun Spray, High Temperature Oxidation, WC-12Co, Cr3C2-25NiCr coating

Abstract

The high-quality ASTM A213 (T91) boiler steel was methodically coated with two different types of coatings using the detonation gun spray technique, a complicated and exact procedure. These coatings, which included WC-12Co and Cr3C2-25NiCr, were selected for their outstanding protective qualities. The pristine ASTM A213 (T91) steel as well as the samples with these coatings were then subjected to a rigorous and in-depth assessment using cyclic oxidation. In order to simulate the genuine effectiveness of these coatings under difficult conditions, the samples were put through a rigorous test that comprised heating them to 700 °C for 50 full cycles in an air atmosphere. Precise weight change data was carefully collected and analysed to capture and quantify the effect of oxidation over time, revealing light on the oxidation kinetics regulating these materials. In addition, cutting-edge analytical methods like X-ray Diffraction (XRD), Energy Dispersive X-ray Spectroscopy (EDS), and Field Emission Scanning Electron Microscopy (FE-SEM) were used to decipher the complex morphology and content of the exposed samples. It was a fascinating discovery that the Cr3C2-25NiCr coating stood out as the better option in this tough environment, demonstrating great skill in protecting the basic steel against the unrelenting forces of corrosion. This study emphasizes the crucial role coatings play in protecting the integrity of high-performance materials exposed to harsh environments.

Downloads

Download data is not yet available.

References

Arivazhagan, N., Narayanan, S., Singh, S., Prakash, S., Reddy, G.M. (2012). High temperature corrosion studies on friction welded low alloy steel and stainless steel in air and molten state environment at 650°C. Mater. Des. 34, 459-468. https://doi.org/10.1016/j.matdes.2011.08.034

Bala, N., Singh, H., Prakash, S. (2010). Accelerated hot corrosion studies of cold-sprayed Ni-50Cr coatings on boiler steels. Mater. Des. 31 (1), 244-253. https://doi.org/10.1016/j.matdes.2009.06.033

Chatha, S.S., Sidhu, H.S., Sidhu, B.S. (2012). Characterisation and Corrosion-Erosion behavior of carbide based thermal spray coatings. JMMCE 11 (6), 569-586. https://doi.org/10.4236/jmmce.2012.116041

Cheng, J., Wu, Y., Qian, L., Hong, S., Qiao, L. (2019). High temperature oxidation behaviour and mechanism of high-velocity arc sprayed FeCrNiAlBSi/Cr3C2 coating. Mater. Res. Express 6 (11), 116598. https://doi.org/10.1088/2053-1591/ab4be3

Crawmer, D.E. (2004). Introduction to Coatings, Equipment and Theory. Handbook of Thermal Spray Technology, Davis JR, editor. ASM International, Materials Park, OH, USA, pp. 43-46.

Das, A., Barrenkala, D., Das S.R., Patel, S.K., Somani, N., Kumar, C.S. (2024). Comparative performance evaluation between ta-C and TiAlCrN coated tools during milling of additively manufactured CFRP composite. Proc. IMechE, Part E: J. Process Mech. Eng. 239 (3), 1154-1170. https://doi.org/10.1177/09544089231223021

Dhand, D., Kumar, P., Grewalm, J.S. (2021). A review of thermal spray coatings for protection of steels from degradation in coal fired power plants. Corros. Rev. 39 (3), 243-268. https://doi.org/10.1515/corrrev-2020-0043

Guo, W., Wu, Y., Zhang, J., Hong, S., Chen, L., Qin, Y. (2015). Comparative study of cyclic oxidation and sulfates-induced hot corrosion behaviour of arc-sprayed Ni-Cr-Ti coatings at moderate temperatures. J. Therm. Spray Technol. 24, 789-797. https://doi.org/10.1007/s11666-015-0222-6

Gupta, N.K., Somani, N., Nandan, G., Phaden, R.K. (2023). Investigation of the mechanical properties of jute and glass fiber reinforced epoxy composite for sustainable and cost-effective applications. Int. J. Interact. Des. Manuf. https://doi.org/10.1007/s12008-023-01684-z

Gupta, N.K., Srivastava, V., Somani, N. (2024). Self-healing materials: fabrication technique and applications-a critical review. Int. J. Interact. Des. Manuf. 18, 6333-6350. https://doi.org/10.1007/s12008-023-01283-y

Kaushal, G., Singh, H., Prakash, S. (2011). Surface engineering, by detonation-gun spray coating, of 347H boiler steel to enhance its high temperature corrosion resistance. Mater. High Temp. 28 (1), 1-11. https://doi.org/10.3184/096034011X12960473417949

Kamal, S., Jayaganthan, R., Prakash, S., Kumar, S. (2008). Hot corrosion behavior of detonation gun sprayed Cr3C2-NiCr coatings on Ni and Fe-based superalloys in Na2SO4-60% V2O5 environment at 900°C. J. Alloys Compd. 463 (1-2), 358-372. https://doi.org/10.1016/j.jallcom.2007.09.019

Kamal, S., Jayaganthan, R., Prakash, S. (2009a). Evaluation of cyclic hot corrosion behaviour of detonation gun sprayed Cr3C2-25%NiCr coatings on nickel- and iron-based superalloys. Surf. Coat. Technol. 203 (8), 1004-1013. https://doi.org/10.1016/j.surfcoat.2008.09.031

Kamal, S., Jayaganthan, R., Prakash, S. (2009b). High temperature oxidation studies of detonation sprayed Cr3C2-NiCr coating on Fe- and Ni-based superalloys on air under cyclic condition at 900˚C. J. Alloys Compd. 472 (1-2), 378-389. https://doi.org/10.1016/j.jallcom.2008.04.087

Kamal, S., Jayaganthan, R., Prakash, S. (2010). Mechanical and microstructural characteristics of detonation gun sprayed NiCrAlY + 0.4 wt% CeO2 coatings on superalloys. Mater. Chem. Phys. 122 (1), 262-268. https://doi.org/10.1016/j.matchemphys.2010.02.046

Kaur, M., Singh, H., Prakash, S. (2011). Surface engineering analysis of detonation-gun sprayed Cr3C2-NiCr coating under high-temperature oxidation and oxidation-erosion environments. Surf. Coat. Technol. 206 (2-3), 530-541. https://doi.org/10.1016/j.surfcoat.2011.07.077

Kumar, M., Singh, H., Singh, N. (2013a). Study of Ni-20Cr coatings for high temperature applications - A review. Arch. Metall. Mater. 58 (2), 523-528. https://doi.org/10.2478/amm-2013-0030

Kumar, S., Deepa, M., Singh, S., Prakash, S. (2013b). Cyclic oxidation behavior of bare and Cr3C2-25(NiCr) coated superalloy at elevated temperature. Adv. Mater. Lett. 4 (10), 754-761. https://doi.org/10.5185/amlett.2013.2428

Mahesh, R.A., Jayaganthan, R., Prakash, S. (2008). Evaluation of hot corrosion behaviour of HVOF sprayed NiCrAl coating on superalloys at 900°C. Mater. Chem. Phys. 111 (2-3), 524-533. https://doi.org/10.1016/j.matchemphys.2008.05.006

Matthews, S., Hyland, M., James, B. (2003). Microhardness variation in relation to carbide development in heat treated Cr3C2-NiCr thermal spray coatings. Acta Mater. 51 (14), 4267-4277. https://doi.org/10.1016/S1359-6454(03)00254-4

Matthews, S.J., James, B.J., Hyland, M.M. (2007). Microstructural influence on erosion behaviour of thermal spray coatings. Mater. Charact. 58 (1), 59-64. https://doi.org/10.1016/j.matchar.2006.03.014

Rajasekaran, B., Sundara, R.G.S., Joshi, S.V., Sundararajan, G. (2008). Influence of detonation gun sprayed alumina coating on AA6063 samples under cyclic loading with and without fretting. Tribol. Int. 41 (4), 315-322. https://doi.org/10.1016/j.triboint.2007.08.007

Roy, M., Pauschitz, A., Polak, R., Franek, F. (2006). Comparative evaluation of ambient temperature friction behaviour of thermal sprayed Cr3C2-25(Ni20Cr) coatings with conventional and nano-crystalline grains. Tribol. Int. 39 (1), 29-38. https://doi.org/10.1016/j.triboint.2004.11.009

Scrivani, A., Ianelli, S., Rossi, A., Groppetti, R., Casadei, F., Rizzi, G. (2001). A contribution to the surface analysis and characterisation of HVOF coatings for petrochemical applications. Wear 250 (1-12), 107-113. https://doi.org/10.1016/S0043-1648(01)00621-4

Shibe, V., Chawla, V. (2019). Erosion studies of D-Gun-sprayed WC-12%Co, Cr3C2-25%NiCr and Al2O3-13%TiO2 coatings on ASTM A36 steel. J. Therm. Spray Technol. 28. 2015-2028. https://doi.org/10.1007/s11666-019-00950-5

Sidhu, T.S., Prakash,a S., Agarwa, R.D. (2005). Studies on the properties of high velocity oxy-fuel thermal spray coatings for high temperature applications. Mater. Sci. 41 (6), 805-823. https://doi.org/10.1007/s11003-006-0047-z

Sidhu, T.S., Malik, A., Prakash. S., Agrawal, R.D. (2007). Oxidation and hot corrosion resistance of HVOF WC-NiCrFeSiB coating on Ni- and Fe-based superalloys at 800 °C. J. Therm. Spray Technol.16, 844-849. https://doi.org/10.1007/s11666-007-9106-8

Sidhu, H.S., Sidhu, B.S., Prakash, S. (2006a). Mechanical and microstructural properties of HVOF sprayed WC-Co and Cr3C2-NiCr coatings on boiler tube steels using LPG as the fuel gas. J. Mater. Process. Technol. 171 (21), 77-82. https://doi.org/10.1016/j.jmatprotec.2005.06.058

Sidhu, H.S., Prakash, S., Agrawal, R.D. (2006b). Hot corrosion performance of a NiCr coated Ni-based alloy. Scripta Mater. 55 (2), 179-182. https://doi.org/10.1016/j.scriptamat.2006.03.054

Sundararajan, G., Prasad, K.U.M., Rao, D.S., Joshi, S.V. (1998). A comparative study of tribological behavior of plasma and D-gun sprayed coatings under different wear modes. J. Mater. Eng. Perform. 7, 343-351. https://doi.org/10.1361/105994998770347783

Ul-Hamid, A. (2003). Diverse scaling behavior of the Ni-20Cr alloy. Mater. Chem. Phys. 80 (1), 135-142. https://doi.org/10.1016/S0254-0584(02)00448-0

Wang, J., Zhang, L., Sun, B., Zhou, Y. (2000). Study of the Cr3C2-NiCr detonation spray coatings. Surf. Coat. Technol. 130 (1), 69-73. https://doi.org/10.1016/S0257-8972(00)00677-0

Wu, Y., Wang, F., Hua, W., Gong, J., Sun, C., Wen, L.S. (2003). Oxidation behavior of thermal barrier coatings obtained by detonation spraying. Surf. Coat. Technol. 166 (2-3), 189-194. https://doi.org/10.1016/S0257-8972(02)00783-1