R.D. Agrawal

Performance of high-velocity oxyfuel-sprayed coatings on an fe-based superalloy in Na2SO4-60%V2O5 environment at 900 °C. Part II: Hot corrosion behavior of the coatings

NiCrBSi, Cr3C2-NiCr, Ni-20Cr, and Stellite-6 coatings were deposited on an Fe-based superalloy by the high-velocity oxyfuel (HVOF) thermal spray process. The hot corrosion behavior of the coatings in an aggressive environment of Na2SO4-60%V2O5 at 900 °C under cyclic conditions was studied. The thermogravimetric technique was used to establish the kinetics of corrosion. X-ray diffraction, scanning electron microscopy/energy-dispersive x-ray and electron probe microanalysis techniques were used to analyze the corrosion products. Hot corrosion resistances of all the coatings were found to be better than the uncoated superalloy. The Ni-20Cr coating was found to be the most protective, followed by Cr3C2-NiCr coatings. The Ni-20Cr coating had reduced the mass gain by 90% of that gained by the uncoated superalloy. The hot corrosion resistance shown by the Cr3C2-NiCr coating was slightly better compared with the NiCrBSi coating; however, both of the coatings performed better than the Stellite-6 coating. The Stellite-6 coating was the least effective among the coatings studied, but it was still successful in decreasing the mass gain to about one fourth compared with the uncoated superalloy. The formation of oxides and spinels of nickel, chromium, or cobalt may be contributing to the development of hot corrosion resistance in the coatings. This article focuses on the hot corrosion behavior of HVOF coatings. The characterization of these coatings has been presented in part I included in this issue.

Characterizations and hot corrosion resistance of Cr3C2-NiCr coating on Ni-base superalloys in an aggressive environment

In the current study, Cr3C2-NiCr coating was deposited on the Ni-base superalloys by using high velocity oxyfuel (HVOF) process for high temperature corrosive environment applications. Optical microscopy (OM), x-ray diffraction (XRD), scanning electron microscopy/energy-dispersive analysis (SEM/EDAX), microhardness tester, and electro probe microanalyzer (EMPA) techniques were used to characterize the coating with regard to coating thickness, porosity, microhardness, and microstructure. The thermogravimetric technique was used to establish kinetics of corrosion. The hot corrosion behaviors of the bare and Cr3C2-NiCr coated superalloys were studied after exposure to aggressive environment of Na2SO4-60% V2O5 salt mixture at 900 °C under cyclic conditions. The structure of the as-sprayed Cr3C2-NiCr coating mainly consisted of γ-nickel solid solution along with minor phases of Cr7C3 and Cr2O3. Coating has porosity less than 1.5% and microhardness in the range of 850–900 Hv (Vickers hardness). Some inclusions, unmelted and semimelted powder particles were observed in the structure of the coatings. The Cr3C2-NiCr coating has imparted necessary resistance to hot corrosion, which has been attributed to the formation of oxides of nickel and chromium, and spinel of nickel-chromium.

Hot corrosion resistance of high-velocity oxyfuel sprayed coatings on a nickel-base superalloy in molten salt environment

No alloy is immune to hot corrosion attack indefinitely. Coatings can extend the lives of substrate materials used at higher temperatures in corrosive environments by forming protective oxides layers that are reasonably effective for long-term applications. This article is concerned with studying the performance of high-velocity oxyfuel (HVOF) sprayed NiCrBSi, Cr3C2−NiCr, Ni−20Cr, and Stellite-6 coatings on a nickel-base superalloy at 900 °C in the molten salt (Na2SO4-60% V2O5) environment under cyclic oxidation conditions. The thermogravimetric technique was used to establish kinetics of corrosion. Optical microscope, x-ray diffraction, scanning electron microscopy/electron dispersive analysis by x-ray (SEM/EDAX), and electron probe microanalysis (EPMA) techniques were used to characterize the as-sprayed coatings and corrosion products. The bare superalloy suffered somewhat accelerated corrosion in the given environmental conditions. whereas hot corrosion resistance of all the coated superalloys was found to be better. Among the coating studied, Ni−20Cr coated superalloy imparted maximum hot corrosion resistance, whereas Stellite-6 coated indicated minimum resistance. The hot corrosion resistance of all the coatings may be attributed to the formation of oxides and spinels of nickel, chromium, or cobalt.