Thermal spray coatings enhance one or more surface properties of engineering components. In this work, NiCrSiBCFe-WC-Co composite coating powder is deposited over SA213-T12 boiler steel using the high velocity oxy fuel spraying (HVOF) and low velocity oxy fuel spraying (LVOF) thermal spray methods to improve erosion performance. XRD and scanning electron microscopy (SEM)/energy dispersive spectroscopy (EDS) were used to examine the surfaces and constituents of as-deposited specimens, whereas SEM was used to investigate the eroded specimens. The erosion behaviours of developed coatings were investigated at 30° and 90° impact angles, 53 m/s and 400°C. XRD analysis of the HVOF coating showed an additional peaks of NiCo2O4, SiC and Ni2B with common peaks Ni, WC, W2C, Cr23C6 and C6(Cr,Co,Ni)23 to that of LVOF coating. HVOF-sprayed coating demonstrated higher microhardness and adhesion strength with lower porosity than LVOF-sprayed coating. The HVOF-sprayed NiCrSiBCFe-WC-Co coating demonstrated comparatively better erosion resistance than LVOF-sprayed NiCrSiBCFe-WC-Co coating, attributed to its superior properties. The mechanism of erosion, concerning the different characteristics of the coatings, is discussed.
WuHWangSZhaoQ, et al.High-temperature corrosion data and mechanisms for T122, Super 304H and HR3C after 15 years in 1000MW ultra-supercritical power plant. Mater High Temp2023; 40: 88–98.
2.
SinghJNathSK. Surface and bulk modification techniques to mitigate silt erosion in hydro turbines: a review of techniques and parameters. Surf Eng2022; 38: 288–302.
3.
ČesánekZLencováKSchubertJ, et al.High-temperature corrosion behavior of selected HVOF-sprayed super-alloy based coatings in aggressive environment at 800 °C. Mater2023; 16: 4492.
4.
MedvedovskiEMendozaGLVargasG. Influence of boronizing on steel performance under erosion-abrasion-corrosion conditions simulating downhole oil production. Corros Mater Degrad2021; 2: 293–324.
5.
LiQLiuB. Erosion-corrosion of gathering pipeline steel in oil-water-sand multiphase flow. Met2023; 13: 80.
6.
GoyalKSinghDSinghH, et al.High temperature corrosion behaviour of ZrO2 reinforced Cr2O3 composite coatings in molten salt environment. Anti-Corros Methods Mater2023; 70: 189–196.
7.
ChenYWuHChenY, et al.Erosion-corrosion coupling analysis of shale gas production pipe. Eng Fail Anal2022; 13: 106308.
8.
DigvijayGBWalmikSRNagarajM. High temperature erosion and sliding wear of thermal sprayed WC–Cr3C2–Ni coatings. Mater High Temp2021; 38: 464–474.
9.
SinghSKaurM. Solid particle erosion behaviour of NiCrFeSiBC/Cr3C2 composite coatings – Part II. Surf Eng2016; 32: 475–489.
10.
SinghJSinghSVasudevH, et al.Neural computing and Taguchi’s method based study on erosion of advanced Mo2C–WC10Co4Cr coating for the centrifugal pump. Adv Mater Process Technol2023: 1–13. DOI: https://doi.org/10.1080/2374068X.2023.2221884
11.
AgnihotriAKalsiSSKansalH. Effect of burnishing on HVOF coated boiler steel against hot corrosion in actual boiler environment. Surf Eng2023; 39: 559–571.
12.
GovandeARChandakASunilBR, et al.Carbide-based thermal spray coatings: a review on performance characteristics and post-treatment. Int J Refract Met Hard Mater2022; 103: 105772.
13.
LencováKNetrvalováMFVostřákM, et al.Hot corrosion behavior of TWAS and HVOF NiCr-based coatings in molten salt. Mater2023; 16: 1712.
14.
FurugakiTTakahashiHHayashiS. Breakdown of protective Cr-rich oxide scale formed on heat-resistant steels for superheater tubes in a waste power generation boiler. High Temp Corros Mater2024; 101: 61–78.
15.
ChawlaVChawlaAPuriD, et al.Hot corrosion & erosion problems in coal-based power plants in India and possible solutions – A review. J Miner Mater Charact Eng2011; 10: 367–385.
16.
ThongyougPChandra-AmbhornSTungtrongpairojJ. The degradation of oxide layer on Cr-containing steels in simulated atmospheres on carbothermic reduction. Mater High Temp2022; 39: 1–11.
17.
RameshMRPrakashSNathSK, et al.Solid particle erosion of HVOF sprayed WC-Co/NiCrFeSiB coatings. Wear2010; 269: 197–205.
18.
KaruanaFPrismantokoASuhendraN, et al.Investigation of austenitic stainless steel corrosion resistance against ash deposits from co-combustion coal and biomass waste. Eng Fail Anal2023; 150: 107368.
19.
ZakeriABahmaniERamazaniA. A review on the enhancement of mechanical and tribological properties of MCrAlY coatings reinforced by dispersed micro and nanoparticles. Energies2022; 15: 1914.
20.
BalaNSinghHKarthikeyanJ, et al.Performance of cold sprayed Ni-20Cr and Ni-50Cr coatings on SA 516 steel in actual industrial environment of a coal-fired boiler. Mater Corros2013; 63: 1–11.
21.
SinghPKMishraSB. Erosion performance of detonation gun deposited WC–12Co, stellite 6 and stellite 21 coatings on SAE213-T12 steel. Tribol Mater Surf Interfaces2020; 14: 229–239.
22.
MishraSBChandraKPrakashS. Studies on erosion behaviour of plasma sprayed coatings on a Ni-based superalloy. Wear2006; 260: 422–432.
23.
MishraSBPrakashS. Erosion-corrosion behaviour Ni-20Cr plasma coating in actual boiler environment. Surf Eng2014; 31: 29–38.
24.
KaluIEInglisHMKokS. Prediction of the time to failure of boiler tubes flawed with localized erosion. J Press Vessel Technol2023; 145: 021502.
25.
DasSKGodiwallaKMMehrotraSP, et al.Analytical model for erosion behaviour of impacted fly-ash particles on coal-fired boiler components. Sadhana2016; 31: 583–595.
26.
SinghPKMishraSB. Studies on solid particle erosion behaviour of D-Gun sprayed WC-Co, Stellite 6 and Stellite 21 coatings on SAE213-T12 boiler steel at 400°C temperature. Surf Coat Technol2020; 385: 125353.
KašparováMZahálkaFHoudkováS, et al.Abrasive wear of WC-NiMoCrFeCo thermally sprayed coatings in dependence on different types of abrasive sands. Kovove Mater2010; 48: 73–85.
29.
KumarRKumarSMehrotraSP. Towards sustainable solutions for fly ash through mechanical activation. Resour Conserv Recycling2007; 52: 157–179.
30.
ASTM standard. Designation: C618−22, standard specification for Coal Fly Ash and raw or Calcined natural Pozzolan for use in concrete. West Conshohocken, PA: ASTM International, 2022.
31.
KumarKKumarSGillHS. Role of surface modification techniques to prevent failure of components subjected to the fireside of boilers. J Fail Anal Prev2023; 23: 1–15.
32.
KumarSKumarR. Influence of processing conditions on the properties of thermal sprayed coating: a review. Surf Eng2021; 37: 1339–1372.
33.
LiCJLuoXTDongXY, et al.Recent research advances in plasma spraying of bulk-like dense metal coatings with metallurgically bonded lamellae. J Therm Spray Tech2022; 31: 5–27.
34.
SatyaNWMudiantoroSWinartoW. Bond strength, hardness, and microstructure analysis of stellite coating applied on 410 steel surface using flame spray, plasma spray, and high-velocity oxyfuel spray process. IOP Conf Ser Mater Sci Eng2020; 924: 012016.
35.
RajendranPRDuraisamyTSeshadriRC, et al.Optimisation of HVOF spray process parameters to achieve minimum porosity and maximum hardness in WC-10Ni-5Cr coatings. Coatings2022; 12: 339.
36.
ZhaiHOuMCuiS, et al.Characterizations of the deposition behavior and mechanical properties of detonation sprayed Fe-based amorphous coatings. J Mater Res Technol2022; 18: 2506–2518.
37.
SathishMRadhikaNSalehB. A critical review on functionally graded coatings: methods, properties and challenges. Compos Part B Eng2021; 225: 109278.
38.
MishraNKMishraSBKumarR. Characterisation and oxidation of LVOF sprayed Al2O3-40%TiO2 coating on superalloys. Surf Eng2015; 31: 349–353.
39.
MishraNKMishraSB. Hot corrosion performance of LVOF sprayed Al2O3–40% TiO2 coating on Superni 601 and Superco 605 superalloys at 800 and 900°C. Bull Mater Sci2015; 38: 1679–1685.
40.
MishraNKMishraSBKumarR. Oxidation resistance of low-velocity oxy fuel- sprayed Al2O3-13TiO2 coating on nickel-based superalloys at 800°C. Surf Coat Technol2014; 260: 23–27.
41.
TiwariSMishraSB. Low velocity oxy fuel spraying of hydroxyapatite coating on a multifunctional UNS S31254 austenitic stainless steel. Proc Inst Mech Eng H2021; 235: 958–972.
42.
YangGJLiJCZangJS. High-temperature erosion of HVOF sprayed Cr3C2-NiCr coating and mild steel for boiler tubes. J Therm Spray Tech2008; 17: 782–787.
43.
BalaNSinghHPrakashS. Performance of cold sprayed Ni based coatings in actual boiler environment. Surf Coat Technol2017; 318: 50–61.
44.
VashishthaNSapateSGGahlotJS, et al.Tribological properties of HVOF sprayed WC-Cr3C2-Ni coating. Mater Res Express2019; 6: 1–12.
45.
DuPLuCHuH, et al.Study of the tribological properties of HVOF-sprayed Ni-based coatings on Ti6Al4 V titanium alloys. Coatings2022; 12: 1–13.
46.
SomervuorMVarisTOksaM, et al.Comparative study on the corrosion performance of APS-, HVOF-, and HVAF-sprayed NiCr and NiCrBSi coatings in NaCl solutions. J Therm Spray Tech2022; 31: 1581–1597.
47.
HuangSZhouJSunK, et al.Microstructural characteristics of plasma sprayed NiCrBSi coatings and their wear and corrosion behaviors. Coatings2021; 11: 170.
48.
ZhengXZhengKChangJ, et al.Microstructure, mechanical properties and reciprocating wear properties of diamond grits-reinforced NiCrBSi composite coatings on 42CrMo. Surf Coat Technol2022; 445: 128703.
49.
AliabadiMKhodabakhshiFSoltaniR, et al.Modification of flame-sprayed NiCrBSi alloy wear-resistant coating by friction stir processing and furnace re-melting treatments. Surf Coat Technol2023; 455: 129236.
50.
WangXWangM. Research on the preparation process and performance of a wear-resistant and corrosion-resistant coating. Crystals2022; 12: 591.
51.
QiaoLWuYHongS, et al.Wet abrasive wear behavior of WC-based cermet coatings prepared by HVOF spraying. Ceram Int2021; 47: 1829–1836.
52.
AzzougRMebdouaYHellalF, et al.Analysis of microstructure, mechanical indentation and corrosive behavior of a thermally sprayed NiFeCrBSi-WC composite coating. J Alloys Compd2022; 900: 163505.
53.
PereiraJCTaboadaMCNiklasA, et al.Influence of the chemical composition on the solidification path, strengthening mechanisms and hardness of Ni-Cr-Si-Fe-B self-fluxing alloys obtained by laser-directed energy deposition. J Manuf Mater Process2023; 7: 110.
54.
PraveenASArjunanA. High-temperature oxidation and erosion of HVOF sprayed NiCrSiB/Al2O3 and NiCrSiB/WC single bond Co coatings. Appl Surf Sci Adv2022; 7: 100191.
55.
ZunakeLKalyankarVD. On the performance of weld overlay characteristics of Ni–Cr–Si–B deposition on 304 ASS using synergetic pulse-GMAW process. Sci and Technol of Weld Join2021; 26: 1–11.
56.
ShaJChenLYLiuYT, et al.Phase transformation-induced improvement in hardness and high-temperature wear resistance of plasma-sprayed and remelted NiCrBSi/WC coatings. Metals2020; 10: 1688.
57.
AbderrahmaneAGacebMCheikhM, et al.Wear behavior and microstructure of thermally sprayed NiCrBSiFeC and composite NiCrBSiFeC-WC(co) coatings. Mater Sci2021; 27: 175–183.
58.
JaiswalAKGovandeARVenkat KiranKU, et al.Effect of argon gas environment on high temperature sliding wear characteristics of NiCrBSi laser clad. Mater Today Proc2023; 78: 682–687.
TiwariSMishraSB. LVOF Sprayed ti-HAp composite coatings for internal fixation devices in orthopaedic applications. Surf Coat Technol2023; 474: 130054.
61.
ASTM standard. Designation: G76-95, standard test method for conducting erosion tests by solid particle impingement using gas Jets. West Conshohocken, PA: ASTM International, 2000.
62.
ZhangFGouHZhangW, et al.Interface microstructure and abrasive wear properties of WC-iron matrix composites with Ni, Mo, Fe added to the preforms. J Mater Res Technol2023; 24: 4218–4231.
63.
MukasyanAMLinYCRogachevAS, et al.Direct combustion synthesis of silicon carbide nanopowder from the elements. J Am Ceram Soc2013; 96: 111–117.
64.
ÖzkavakHŞahinSAlkanZ. Comparison of wear properties of HVOF sprayed WC-Co and WC-CoCr coatings on Al alloys. Mater Res Express2019; 6: 096427.
65.
DasAShuklaM. Surface morphology, bioactivity, and antibacterial studies of pulsed laser deposited hydroxyapatite coatings on stainless steel 254 for orthopedic implant applications. Proc IMechE Part L: J Mater: Des Appl2019; 233: 120–127.
66.
KimJZollingerD. Effects of shape and bond strength on adhesive failure of joint sealants. Transp Res Rec2021; 2675: 203–212.
67.
WeiKChenYLiM, et al.Strength and failure mechanism of composite-steel adhesive bond single lap joints. Adv Mater Sci Eng2018; 2018: 5810180.
68.
OmaireySJayasreeNKazilasM. Defects and uncertainties of adhesively bonded composite joints. SN Appl Sci2021; 3: 769–782.
69.
BudzikMKWolfahrtMReisP, et al.Testing mechanical performance of adhesively bonded composite joints in engineering applications: an overview. J Adhes2022; 98: 2133–2209.
70.
RaghavendraNKKumarRKSaravananV, et al.Solid particle erosion of HVOF sprayed (35WC-Co/NiCrBSi) coating at higher temperature. J of CPRI2016; 12: 351–362.
71.
DwivediSPSharmaSSrivastavaAP, et al.Homogeneity, metallurgical, mechanical, wear, and corrosion behavior of Ni and B4C coatings deposited on 304 stainless steels developed by microwave cladding technique. J Mater Res Technol2023; 27: 5854–5867.
72.
BhosaleDGPrabhuTRRathodWS. Sliding and erosion wear behaviour of thermal sprayed WC-Cr3C2-Ni coatings. Surf Coat Technol2020; 400: 126192.
73.
LiWAssadiHGärtnerF, et al.A review of advanced composite and nanostructured coatings by solid-state cold spraying process. Crit Rev Solid State Mater Sci2018; 44: 1–48.
74.
FanKJiangWLuzinV, et al.Influence of WC particle size on the mechanical properties and residual stress of HVOF thermally sprayed WC–10Co–4Cr coatings. Materials2022; 15: 5537.
75.
PalanisamyKGangoluSAntonyJM. Effects of HVOF spray parameters on porosity and hardness of 316L SS coated Mg AZ80 alloy. Surf Coat Technol2022; 448: 128898.
76.
PalSSarkarRJayramV. Characterization of thermal stability and high-temperature tribological behavior of electroless Ni-B coating. Metall Mater Trans A2018; 49: 3217–3236.
77.
KarnAKAgrawalRKumarA, et al.Deposition and process parameter optimization of electroless Ni-B coating from a stabilizer free bath to achieve enhanced microhardness, scratch-hardness and adhesion using Taguchi’s methodology. Eng Res Express2023; 5: 036001.
YangGJLiCJZhangSJ, et al.High-temperature erosion of HVOF sprayed Cr3C2-NiCr coating and mild steel for boiler tubes. J Therm Spray Technol2008; 17: 782–787.
80.
KazasidisMVernaEYinS, et al.The effect of heat treatment and impact angle on the erosion behavior of nickel-tungsten carbide cold spray coating using response surface methodology. Emergent Mater2022; 4: 1605–1618.
81.
PatelMPatelDSekarS, et al.Study of solid particle erosion behaviour of SS 304 at room temperature. Procedia Technol2016; 23: 288–295.
82.
AlidokhtSAVoPYueS, et al.Erosive wear behavior of cold-sprayed Ni-WC composite coating. Wear2017; 376-377: 566–577.
