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

    1 Citation (Scopus)


    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
    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


    ConferenceInternational Thermal Spray Conference, ITSC 2012
    Abbreviated titleITSC
    Country/TerritoryUnited States


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