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CHIIITARA

UNIVERSITY
Punj ab

ampu s : Chandigarh-P attala National Highway

Tehsil Rajpura, Distt .Patiala-l 404A1 GNDIA)


Phone No.:+9 1.1762-50708

4,

rsBN 978-8 |

-92A9 13 -8-9

507086 Fax No.: +9 L.L762-507085

Administrative Office: Saraswati Kendra,


SCO 160-161, Sectot 9 C,Chandigarh 160 009, India'
Tel: +91 .172.4090900
www.chitkara.edu.in

Hot-Corrosion Performance of High-Velocity


O*y-Fuel Sprayed Coatings: A Revtew
Harkulvinder SinghI*, Sukhpal Singh Chathaz,Hazoor Singh Sidhu3
'Bhai Gurdas Polyechnic college ,Sangrur, Punjab, India-14001, (Email: bgpcsangrur2007@gmail.com )
2Yadavindra
College of Engineering, Punjabi University Guru Kashi Campus, Talwandi Sabo, Punjab, India-l51302

3YadavindraCoIlegeofEngineerin*,,,,!lili$,ffis,TalwandiSabo,Punjab,India-l5l302
(Email: hazoors@vahoo.com), *Corresponding author email: bqpcsanqrur200T@).smail.com

Abstrsct- Hot corrosion is a serious problem in boilers,

gas turbines, internal combustion engines, and


industrial waste incinerators. It consumes the

materials at an unpredictably rapid rate. The use of


protective coatings has been an answer to remedy the
lack of high temperature surface stability of metals
and alloys in harsh environments. Coating can be
deposited by electric arc spray, physical vapour
deposition, detonation spraying, llame spray, vacuum

temperature hot corrosion (LTHC). High temperature hot


corrosion (HTHC) also designated as Type l, occurs at
temperatures in the 800 to 950oC range. It is caused by
molten r salt deposition on the coating surface. The
primarily active constituent of this salt is sodium sulphate
Na2SOa. Low temperature hot corrosion (LTHC), also
known as Type 2 , occurs in the 650-750" C range. The
low temperature hot corrosion mechanism involves acidic

fluxing of protective oxides by sulphur trioxide (SO3)


dissolved in molten sulphates (N bala, 2010).

plasma spray, low pressure plasma spray, high velocity

oxy fuel by sputtering or by evaporation. High-velocity

il.

oxy-fuel GfVOF) spraying is a new and rapidly


developing technology in combating high-temperature
corrosion. HVOF coatings have very low porosity, high
hardness, high abrasive resistance, good wear
resistance with a strong ability to resist hightemperature corrosion resistance. This study is done
with the aim of putting together the performance
capabilities and applications of HVOF process.
KeTwords

-Hot corrosion, HVOF, Coatings, Thermal


spray

I.

INrnooucrroN

limit of use of materials at the upper end of their


by allowing the mechanical

The corrosion of materials causes great loss in the


industrial applications, especially under some extreme

performance capabilities

properties of substrate materials to be maintained while


protecting them against the wear and corrosion. Coating
can be deposited by electric arc spray, physical vapour
deposition, detonation spraylng, flame spray, vacuum
plasma spray, low pressure plasma spray, high velocity
oxy fuel, by sputtering or by evaporation ( R Bhatia et al,
20r0).

conditions, the corrosive atmosphere and high temperature


( Teng and Dian, 2009). Hot corrosion is an accelerated
form ofoxidation that occurs at higher temperature in the
presence of salt contaminants such as Na2SOa. NaCl, V2O5
that combine to form molten deposits, which damage the
protective oxide layer ( N.eliaz et aL,2002). Hot corrosion
is a serious problem in boilers, gas turbines, internal
combustion engines, and industrial waste incinerators. As

IIL

consequence the load-carrying abilities of the


components are reduced (T.S.Sidhu et al, 2006). In
combustion products of fuel oil, sulfur is typically present

HTGH

vEl,ocrry oxy

FUEL

(HVOF) rnocrss

High-velocity oxy-fuel (HVOF) spraying is a new and

rapidly developing technology in combating hightemperature corrosion. The hypersonic velocity of the
flame shortens the time of interaction between the powder
and flame, whereas low temperature of flame limits the
grain growth and decomposition of coating. Due to the
high impact velocity of particles the coatings show a high
adhesive strength, high cohesive strength of individual

which occurs when the metals are heated in the


temperature range of700-900oC, in the presence ofsulfate
as Na2SOa,

deposits. Vanadium as an impurity in fuel oil causes


serious corrosion problems because of the formation of

V2O5[smail and Anees, 2004).

NEED oF COATINGS

The development of coating technology stems from, and


is determined by, the progress of knowledge on high
temperature corrosion. Hot components of gas turbines
and energy systems operating in aggressive environments
are subjected to a number of modes of attacks termed as
high temperature corrosion, which include oxidation,
sulphidising, carburizing, chlorination, erosion and hot
corrosion induced by molten salts. The use of protective
coatings has been an answer to remedy the lack of high
temperature surface stability of metals and alloys in harsh
environments. Coating provides a way of extending the

It is now currently

accepted that protective coatings on superalloys encounter - splats, uniform microstructure, high density and low
two types of high temperature corrosion degradation i.e porosity with a strong ability to resist high-temperature

High

temperature

hot

corrosion (HTHC) and

LcA^/

corrosion resistance (H.Sidhu et al, 2005). This spraying

lnternational Conference on Advances in Materials and Manufacturing Technology-z}Ll


82

\
system enables metals and alloys with high melting point
up to about 2000'C to be deposited on the target surface.
These features are suitable for a deposition of corrosion
resistant coatings (T.Sidhu et a1,2005A).In the HVOF
process the powder/wire material is melted and propelled

Fig-3 shows the velocity and temperature comparison of


HVOF process with its other counterparts.The high
resistance of high-chromium, nickel-chromium alloys to
high-temperature oxidation and corrosion allows them to
be widely used as welded and thermally sprayed coatings
at a high velocity toward the surface with the use of in fossil fuel-fired boilers, waste incineration boilers, and
oxygen and fuel gas mixtures as shown in fig.I. The most , electric furnaces. The HVOF process is often used to
important parameter regarding the coating quality is deposit high-chromium, nickel-chromium coatings onto
powder particle velocity, which
the outer surfaces ofvarious parts ofboilers to prevent the
penetration of hot gases, molten ash, and liquids to less
noble carbon steel boiler tubes (T.Sidhu et al, 20058) .The
ExpoB*eff
HVOF coatings have higher bond strengths than for the
plasma-spray coatings by 25%. The better adhesion
Ols6{dtnoorrtffi
strength of the HVOF coatings is attributed to the better
mechanical interlocking of the sprayed droplets with the
substrate due to the high kinetic energy experienced by the

impinging particles. Hence, the HVOF coatings

can

perform very well in corrosive environments as compared


to other processes (T.Sidhu et aI,2005C).

?Bc!s s,S rsme !6a

o*,

Fig-l Schematic diagram, of High

IV.

Ur"l process ( V. hotea et

ffiO
for powder combustion spray to
1000m/s for HVOF spraying. HVOF process of thermal
spray have particle high speed that produce low porosity
coatings , oxides ,better bond strength and hardness as
compared to its other counterparts as shown in fig.2 (
GR.heath et al , 2008 ).
ranges from l00m/s

HVOF

CoATD,TGS

Cr3C2-NiCr coating was deposited on SAE-347H boiler


steel by HVOF spray process and investigated at 700'C

for 50 cycles in Na2SOa-Fe2(SOa) molten salt, as well as


air environments. The HVOF spray Cr3C2-NiCr coating
was found to be successful in maintaining its adherence in
both the environments. The surface oxide scales were also
found to be intact. The formation of chromium rich oxide

for the better hot


corrosion/oxidation resistance- in the coated steel (M. Kaur
et at,2009). The Fe-based superalloy Superfer 800H was
used as a subsfrate material and coating alloys Cr3C2NiCrC alloy powders, namely as-atomized powder with a
scale might haye contributed

conventional coarse-grained structure and cryomilled


powder with a nanocrystalline structure, were employed
on medium steel with HVAF process. Heat treatment was
conducted at 650 oC in air. Samples were removed after
10, 30, 50, 100, 150 and 200 hr. Both the as-sprayed
NiCrC coatings possessed a compact microstrucfure which
exhibited a more homogeneous morphology with
uniformly distributed fine carbide dispersions and a much
Fig-2 Characteristics ofthe HVOF and standard

higher microhardness. The nanoskucture coating exhibited

fcl

excellent thermal stability, whose average grain size


stabilized at about 100 nm after 50 h of exposure at

ir*r.FhllrlPl.sntt,npsd8G

lf-

0mt&$00

650 "C (K.Tao et al, 2005).

NiCr and Stellite-6 coatings have been formulated on


boiler tube steels namely ASTM-SA-2I0 Grade Al,
ASTM-SA213-T-Il and ASTM-SA2l3-T-22 by HVOF

0s0
los08m
SrrPlr0chy.turyldrl

technique using LPG as fuel gas. The results of Stellite-6


coating were better than those of the NiCr coatings for low
value of porosity and surface roughness. Microhardness
measurement across the cross-section of coating showed
that the Stellite-6 coating has higher hardness as compared
to the NiCr coating, although both coatings have high

ffi

hardness values compared

Fig-3 Comparison of various processes (Dorftnan M., 2002) plasmaprocess coatings: (I) hardness,
(ID porcsity (IID oxide content, (tV) bond strength
(V) maximum thickness. (T.Sidhu et a1,20058)

to the substrate

steels

(H.S.sidhu et al, 2010). HVOF process was used to deposit


Ni-based hardfacing NiCrFeSiB alloy powder on boiler

International Conference on Advances in Materials and Manufacturing Technology-2}Ll


83

rube steels designated as SA210 grade-Al, SA2l3-Tll,

and SMI3-T22. Thermocyclic oxidation test were


performed in static air at 900oC in silicon carbide tube
furnace up to 50 cycles. The microstructure of coatings
has a dense and layered structure with porosity less than

0.5%. The superior performance of NiCrFeSiB coating


can be athibuted to continuous and protective thin oxide
scale of amorphous SiOz and Cr2O3 formed on the surface
of the oxidized coatings (M.R.Ramesh et al, 2010). The
coatings of 80Ni-20Cr and 50Ni-50Cr are deposited by
HVOF process and APS (Air plasma spray) on 9Cr-lMo
steel substrate respectively. Steam oxidation test was
carried out at 650oC for 100, 1000 and 3000 hours. HVOF
coatings of both 80Ni-20Cr and 50Ni-50Cr yielded a good

Boilo{

Etl{irufle*t

tlwrll

0" C)

Cr30l

llpr

Crdeplodlrler

.{

protection till 750'C by forming Cr oxide as protective


layer as compared to APS (Sundararajan T et a1,2004).
Ni-20%Cr alloy powders gas and water atomized were
sprayed on mild steel substrates with Top gun HVOF
system with a gaseous propylene fuel and Met-Jet II

$i

i1

Chrlof

NisdCl

rich

ifinlr

kv*r

S{1ilu

7.)

voi&

l{

HVOF system with liquid fuel (kerosene). The results


observed that geatest corrosion protection to the steel

al

substrate is given by coatings produced from gas atomized


Ni-20%Cr powders when sprayed by the liquid fuelled
Met Jet II system. Met Jet II spray system produced
coatings with a smaller amount of oxide and less porosity

(M.E.Aalamialeagha et al, 2003).


Cr3C2-NiCr, NiCr, WC-Co and Stellite-6 alloy coatings
were sprayed on ASTM SA213-TI I steel specimens using
the HVOF process, liquid petroleum gas was used as the
fuel gas. Hot corrosion testing was done on the specimens

after exposure to molten salt at 900oC under cyclic


conditions. NiCr Coating was found to be most protective
followed by the Cr3C2-NiCr coating. WC-Co coating was
least effective to protect the substrate steel. It is concluded
that the formation of Cr2O3, NiO, NiCr2Oa, and CoO in the
coatings may contribute to the development of a better
hot-corrosion resistance (H. S. Sidhu et al, 200 6).

Fig-4 Schematic diagram illustrating the E-C mode for the HVOF
sprayed

Ni-20Cr coating after exposure to boiler environment (G.


Kaushal et al, 2010). Examination of samples revealed
that there is an outermost layer which contains ash
particles such as Al2O3, SiO2, and Fe2O3 deposited from
the boiler environment. Due to this, a thin chromia layer,
being formed by outward diffusion of the chromium from
the coating region and inward diffrrsion of O from the
environment. The outward diffirsion of Cr is evident from
the presence of a Cr-depleted inner layer just below the

thin Cr-rich layer. The coating was found to

The boiler tube steel, ASTM-SA2l0 grade A1 (GrAl)


have been used as substrate and Cr2O3-NiCr, WC-12Co
and stellite-6 alloy powder and Ni-20Cr wire coating is
done with HVOF spraylng operating with oxygen and
LPG as the fuel gases. Cyclic oxidation was performed in
molten salt (Na2SOa,-60yo V2O5) for 50 cycles, The
results of XRD, EDAX and EPMA analysis shows the
porosity of NiCr coating lies in the range of l-3.5Yo that
provided highest resistance to hot corrosion (H.S.Sidhu et

al, 2006). Low carbon steel ASTM-SA2l0 grade Al


(GrAl); lCr-O.SMo steel ASTM-SA2l3- T-l I (Tl l) and
2.25Cr-lMo steel ASTM-SA2|3-T-22 (T22) have been
used as substrate and WC-l2YoCo , Cr3C2-25o/otliCr
powder coating were deposited by HVOF thermal
spraying process with LPG as fuel gas in the thickness
range of 350-380pm. It is observed that WC-Co coatings
has slightly higher hardness as compared to the Cr3C2NiCr coatings and also found lower porosity

Ni-20Cr coating was deposit by HVOF on ASTM-A213


347H boiler steel specimens and the samples with and
without coating were exposed to the super heater zone of a
thermal power plant boiler at a temperature of 973 K
(700"C) under cyclic conditions to ascertain their erosioncorrosion (E-C) behavior. Fig.4 shows Schematic diagram
illustrating the E-C mode for the HVOF sprayed Ni-20Cr
coating after exposure to boiler environment.

have

significant resistance to its oxide scale spallation during


cyclic oxidationexposures; moreover, the coating was
found to have retained its continuous contact with the
substrate steel during these thermal cycles. This indicates
that the coating has good adhesion strength (G. Kaushal et

al,20l0).

V.

CoNcLUSToN

l.Degradation of material in the form of corrosion ,erosion


and wear is a challenge problem faced by the industry
involving in energy generation systems.
2. Thermal spray coating is an flexible and cost eflective
method of improving the life of materials against the
degradation of materials.
3. Among the different thermal spray techniques, High
velocity oxy fuel process is better with regards to
hardness, porosity , adherence strength , corrosion
resistance and wear resistance ofthe coatings.

as compared .

4. Hence HVOF process can be thought of engineering


solution to enhance surface against wear & corrosion

t" degradation

to the Cr3C2-NiCr coating that is desired for hot corrosion


(H.S.Sidhu et al, 2006).

and other surface phenomena's.

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84

RrpsneNcss

tll

12)

t3l

t4l

Aalamialeagha

M. E., Harris S.J., Emamighomi M.,

2003.
lnfluence ofthe HVOF spraying process on the microstructure and
corrosion behavior of Ni-20% Cr coatings. J of materials science.

38,4587 -4596.
Bala N., Singh H., Prakash S., 2010. Accelerated hot corrosion
studies of cold spray Ni-50Cr coating on boiler steels,J. of
Materials and Design. 31,244-253.
Eliaz N., Shemesh G., latanision R.M.,20O2. Hot corro$ion in gas
turbine components. J ofEngineering failure analysis. 9,31-43.
Kaushal G., Singh H., Sprakash S., 2010. High-temperature
erosion-corrosion performance of high-velocity oxyfuel sprayed
Ni-20Cr coating in actual boiler environment. J of metallurgical
and materials transactions a.42

t5I

t6l

Ramesh

M.R., Prakash S., Nath S.K, Sapra

P.K.,

KrishnamurthyN., 2010. Evaluation of thermocyclic oxidation


behavior ofhvof-sprayed NiCrFeSiB coatings on boiler tube steels.
J ofthermal spray technology. 20
Sidhu T.S., Prakash S., Agrawal R.D., 2005. Performance of highvelocity oxyfuel sprayed coatings on an fe-based superalloy in
NazSO+ -607oV2O5 enyironment at 900oC, part ii: hot corrosion
behavior of the coatings, J of materials engineering and
performance. I 5(l ), I 30.

t7l

Sidhu B S., Parkash S., 2006. Characteristic


of HVOF sprayed NiCr and stellite-6 coatings on the
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H S.,

paxameters

t8l

teI

ll0l

llll
u2l

l3]

u4)

information techn ology. 2, I 33-l 39.


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of HVOF sprayed coatings on ASTM (SA2l3-Tl1) steel. J of
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coatings in improving hot corrosion resistance of ASTM-SA2I0
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surface & coatings technology. 200, 5386 - 5394.
Sidhu H S., Sidhu B S., Parkash S., 2006. Mechanical and
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