Optimizing NiCr and FeCr HVOF coating structures for high temperature corrosion protection applications

Maria Oksa (Corresponding Author), Jarkko Metsäjoki

    Research output: Contribution to journalArticleScientificpeer-review

    16 Citations (Scopus)

    Abstract

    In order to achieve a desired dense structure for coatings employed in high temperature corrosion conditions, thermal spray process optimization with diagnostic tools can be applied. In this study, NiCr (51Ni-46Cr-2Si-1Fe) and FeCr (Fe-19Cr-9W-7Nb-4Mo-5B-2C-2Si-1Mn) powders were sprayed with HVOFGF (gas-fueled) and HVOFLF (liquid-fueled) systems, and the spray processes were monitored with diagnostic tools, including SprayWatch for measuring the temperature and velocity of the spray stream, and in situ coating property (ICP measurement) for measuring the stress state. Various spray parameters were applied to attain the best coating characteristics for high temperature applications. Selected coatings were exposed to high temperature corrosion conditions both in laboratory and actual power plant. The coatings were analyzed by microscopic means and mechanical testing. The application of process-structure-properties-performance methodology with the process monitoring, analysis of the coating characteristics, and results of corrosion performance are presented in this paper.
    Original languageEnglish
    Pages (from-to)436-453
    JournalJournal of Thermal Spray Technology
    Volume24
    Issue number3
    DOIs
    Publication statusPublished - 2015
    MoE publication typeA1 Journal article-refereed

    Fingerprint

    Corrosion protection
    corrosion
    coatings
    Coatings
    sprayers
    Corrosion
    Temperature
    High temperature applications
    Mechanical testing
    Process monitoring
    power plants
    Powders
    Power plants
    Gases
    methodology
    optimization
    Liquids
    liquids
    gases

    Keywords

    • coatings
    • corrosion
    • high temperature applications
    • HVOF thermal spraying
    • optimization

    Cite this

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    title = "Optimizing NiCr and FeCr HVOF coating structures for high temperature corrosion protection applications",
    abstract = "In order to achieve a desired dense structure for coatings employed in high temperature corrosion conditions, thermal spray process optimization with diagnostic tools can be applied. In this study, NiCr (51Ni-46Cr-2Si-1Fe) and FeCr (Fe-19Cr-9W-7Nb-4Mo-5B-2C-2Si-1Mn) powders were sprayed with HVOFGF (gas-fueled) and HVOFLF (liquid-fueled) systems, and the spray processes were monitored with diagnostic tools, including SprayWatch for measuring the temperature and velocity of the spray stream, and in situ coating property (ICP measurement) for measuring the stress state. Various spray parameters were applied to attain the best coating characteristics for high temperature applications. Selected coatings were exposed to high temperature corrosion conditions both in laboratory and actual power plant. The coatings were analyzed by microscopic means and mechanical testing. The application of process-structure-properties-performance methodology with the process monitoring, analysis of the coating characteristics, and results of corrosion performance are presented in this paper.",
    keywords = "coatings, corrosion, high temperature applications, HVOF thermal spraying, optimization",
    author = "Maria Oksa and Jarkko Mets{\"a}joki",
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    T1 - Optimizing NiCr and FeCr HVOF coating structures for high temperature corrosion protection applications

    AU - Oksa, Maria

    AU - Metsäjoki, Jarkko

    PY - 2015

    Y1 - 2015

    N2 - In order to achieve a desired dense structure for coatings employed in high temperature corrosion conditions, thermal spray process optimization with diagnostic tools can be applied. In this study, NiCr (51Ni-46Cr-2Si-1Fe) and FeCr (Fe-19Cr-9W-7Nb-4Mo-5B-2C-2Si-1Mn) powders were sprayed with HVOFGF (gas-fueled) and HVOFLF (liquid-fueled) systems, and the spray processes were monitored with diagnostic tools, including SprayWatch for measuring the temperature and velocity of the spray stream, and in situ coating property (ICP measurement) for measuring the stress state. Various spray parameters were applied to attain the best coating characteristics for high temperature applications. Selected coatings were exposed to high temperature corrosion conditions both in laboratory and actual power plant. The coatings were analyzed by microscopic means and mechanical testing. The application of process-structure-properties-performance methodology with the process monitoring, analysis of the coating characteristics, and results of corrosion performance are presented in this paper.

    AB - In order to achieve a desired dense structure for coatings employed in high temperature corrosion conditions, thermal spray process optimization with diagnostic tools can be applied. In this study, NiCr (51Ni-46Cr-2Si-1Fe) and FeCr (Fe-19Cr-9W-7Nb-4Mo-5B-2C-2Si-1Mn) powders were sprayed with HVOFGF (gas-fueled) and HVOFLF (liquid-fueled) systems, and the spray processes were monitored with diagnostic tools, including SprayWatch for measuring the temperature and velocity of the spray stream, and in situ coating property (ICP measurement) for measuring the stress state. Various spray parameters were applied to attain the best coating characteristics for high temperature applications. Selected coatings were exposed to high temperature corrosion conditions both in laboratory and actual power plant. The coatings were analyzed by microscopic means and mechanical testing. The application of process-structure-properties-performance methodology with the process monitoring, analysis of the coating characteristics, and results of corrosion performance are presented in this paper.

    KW - coatings

    KW - corrosion

    KW - high temperature applications

    KW - HVOF thermal spraying

    KW - optimization

    U2 - 10.1007/s11666-014-0192-0

    DO - 10.1007/s11666-014-0192-0

    M3 - Article

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    EP - 453

    JO - Journal of Thermal Spray Technology

    JF - Journal of Thermal Spray Technology

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    ER -