Optimizing NiCr thermal spray coating with process map methodology for high temperature power plant boiler application

Maria Oksa, Tommi Varis, Tomi Suhonen, Mika Jokipii

    Research output: Chapter in Book/Report/Conference proceedingConference article in proceedingsScientificpeer-review

    Abstract

    Alloys with high amount of chromium are used for protection of power plant boilers against the high temperature corrosion, especially heat exchanger surfaces, such as superheaters. Thermal spray coatings can be applied to low alloyed steel in order to enhance the lifetime of the cheap substrate material. In this study NiCr (50Ni49Cr1Fe) powder was sprayed with DJ Hybrid and CJS HVOF techniques, and the spraying process was optimized with process map methodology, including SprayWatch for measuring the temperature and velocity of the spray stream, and ICP (In-situ coating property measurement) for measuring the stress state. Different spraying parameters were applied in order to attain the best suitable coating characteristics for high temperature applications, such as high density and low oxidation stage. The coatings were analyzed e.g. by microscopic means and mechanical testing. The use of process optimization, process-structure-properties methodology, and following coating characteristics are presented
    Original languageEnglish
    Title of host publicationInternational Thermal Spray Conference & Exposition (ITSC 2012)
    Subtitle of host publicationAir, Land, Water and the Human Body: Thermal Spray Science and Applications
    PublisherASM International
    Pages81-86
    ISBN (Print)978-1-63266-679-6
    Publication statusPublished - 2012
    MoE publication typeA4 Article in a conference publication
    EventInternational Thermal Spray Conference, ITSC 2012 - Houston, United States
    Duration: 21 May 201224 May 2012

    Conference

    ConferenceInternational Thermal Spray Conference, ITSC 2012
    Abbreviated titleITSC
    CountryUnited States
    CityHouston
    Period21/05/1224/05/12

    Fingerprint

    Boilers
    Power plants
    Coatings
    Spraying
    Temperature
    Superheaters
    High temperature applications
    Mechanical testing
    Heat exchangers
    Chromium
    Hot Temperature
    Corrosion
    Powders
    Oxidation
    Steel
    Substrates

    Keywords

    • ProperTune

    Cite this

    Oksa, M., Varis, T., Suhonen, T., & Jokipii, M. (2012). Optimizing NiCr thermal spray coating with process map methodology for high temperature power plant boiler application. In International Thermal Spray Conference & Exposition (ITSC 2012): Air, Land, Water and the Human Body: Thermal Spray Science and Applications (pp. 81-86). ASM International.
    Oksa, Maria ; Varis, Tommi ; Suhonen, Tomi ; Jokipii, Mika. / Optimizing NiCr thermal spray coating with process map methodology for high temperature power plant boiler application. International Thermal Spray Conference & Exposition (ITSC 2012): Air, Land, Water and the Human Body: Thermal Spray Science and Applications . ASM International, 2012. pp. 81-86
    @inproceedings{3d847b87c2f0418abc9106ac6e207799,
    title = "Optimizing NiCr thermal spray coating with process map methodology for high temperature power plant boiler application",
    abstract = "Alloys with high amount of chromium are used for protection of power plant boilers against the high temperature corrosion, especially heat exchanger surfaces, such as superheaters. Thermal spray coatings can be applied to low alloyed steel in order to enhance the lifetime of the cheap substrate material. In this study NiCr (50Ni49Cr1Fe) powder was sprayed with DJ Hybrid and CJS HVOF techniques, and the spraying process was optimized with process map methodology, including SprayWatch for measuring the temperature and velocity of the spray stream, and ICP (In-situ coating property measurement) for measuring the stress state. Different spraying parameters were applied in order to attain the best suitable coating characteristics for high temperature applications, such as high density and low oxidation stage. The coatings were analyzed e.g. by microscopic means and mechanical testing. The use of process optimization, process-structure-properties methodology, and following coating characteristics are presented",
    keywords = "ProperTune",
    author = "Maria Oksa and Tommi Varis and Tomi Suhonen and Mika Jokipii",
    note = "Project code: 37397",
    year = "2012",
    language = "English",
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    publisher = "ASM International",
    address = "United States",

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    Oksa, M, Varis, T, Suhonen, T & Jokipii, M 2012, Optimizing NiCr thermal spray coating with process map methodology for high temperature power plant boiler application. in International Thermal Spray Conference & Exposition (ITSC 2012): Air, Land, Water and the Human Body: Thermal Spray Science and Applications . ASM International, pp. 81-86, International Thermal Spray Conference, ITSC 2012, Houston, United States, 21/05/12.

    Optimizing NiCr thermal spray coating with process map methodology for high temperature power plant boiler application. / Oksa, Maria; Varis, Tommi; Suhonen, Tomi; Jokipii, Mika.

    International Thermal Spray Conference & Exposition (ITSC 2012): Air, Land, Water and the Human Body: Thermal Spray Science and Applications . ASM International, 2012. p. 81-86.

    Research output: Chapter in Book/Report/Conference proceedingConference article in proceedingsScientificpeer-review

    TY - GEN

    T1 - Optimizing NiCr thermal spray coating with process map methodology for high temperature power plant boiler application

    AU - Oksa, Maria

    AU - Varis, Tommi

    AU - Suhonen, Tomi

    AU - Jokipii, Mika

    N1 - Project code: 37397

    PY - 2012

    Y1 - 2012

    N2 - Alloys with high amount of chromium are used for protection of power plant boilers against the high temperature corrosion, especially heat exchanger surfaces, such as superheaters. Thermal spray coatings can be applied to low alloyed steel in order to enhance the lifetime of the cheap substrate material. In this study NiCr (50Ni49Cr1Fe) powder was sprayed with DJ Hybrid and CJS HVOF techniques, and the spraying process was optimized with process map methodology, including SprayWatch for measuring the temperature and velocity of the spray stream, and ICP (In-situ coating property measurement) for measuring the stress state. Different spraying parameters were applied in order to attain the best suitable coating characteristics for high temperature applications, such as high density and low oxidation stage. The coatings were analyzed e.g. by microscopic means and mechanical testing. The use of process optimization, process-structure-properties methodology, and following coating characteristics are presented

    AB - Alloys with high amount of chromium are used for protection of power plant boilers against the high temperature corrosion, especially heat exchanger surfaces, such as superheaters. Thermal spray coatings can be applied to low alloyed steel in order to enhance the lifetime of the cheap substrate material. In this study NiCr (50Ni49Cr1Fe) powder was sprayed with DJ Hybrid and CJS HVOF techniques, and the spraying process was optimized with process map methodology, including SprayWatch for measuring the temperature and velocity of the spray stream, and ICP (In-situ coating property measurement) for measuring the stress state. Different spraying parameters were applied in order to attain the best suitable coating characteristics for high temperature applications, such as high density and low oxidation stage. The coatings were analyzed e.g. by microscopic means and mechanical testing. The use of process optimization, process-structure-properties methodology, and following coating characteristics are presented

    KW - ProperTune

    M3 - Conference article in proceedings

    SN - 978-1-63266-679-6

    SP - 81

    EP - 86

    BT - International Thermal Spray Conference & Exposition (ITSC 2012)

    PB - ASM International

    ER -

    Oksa M, Varis T, Suhonen T, Jokipii M. Optimizing NiCr thermal spray coating with process map methodology for high temperature power plant boiler application. In International Thermal Spray Conference & Exposition (ITSC 2012): Air, Land, Water and the Human Body: Thermal Spray Science and Applications . ASM International. 2012. p. 81-86