High-Temperature Solid Particle Erosion Behavior of Partially Oxidized NiCrBSiFe/NiCr Plasma Spray Coatings

Abstract

This paper investigated the solid particle erosion behavior of partially oxidized NiCrBSiFe and NiCr coatings by varying temperature and impact angle. The challenge in the current situation is to process a new system of powders containing metallic and oxide phases. Partially oxidized powders containing metallic and oxide phases were processed by flame spraying the alloy powders into distilled water and allowing the oxide layer to form while keeping the core in the middle of the particle. Partially oxidized coatings were developed on MDN321 steel using the plasma spray technique with feedstock of partially oxidized powders. An air jet erosion test was carried out using Al2O3 erodent of grit size 50 µm at room temperature, 200, 400, 600, and 800°C by varying 30, 45, 60, 75, and 90° impact angles. Coatings were characterized concerning bond strength, porosity, micro-hardness, and density. The effect of temperature and impact angle on volumetric erosion loss was studied using SEM, EDS, and XRD analysis. Partially oxidized NiCrBSiFe coating exhibited better erosion resistance compare with partially oxidized NiCr coating. NiCr coating demonstrates maximum volumetric erosion loss at 45° impact angle, whereas NiCrBSiFe at 60° impact angle under all tested temperatures.