High-Temperature Behavior of a High-Velocity Oxy-Fuel Sprayed Cr3C2-NiCr Coating

High-velocity oxy-fuel (HVOF) sprayed coatings have the potential to enhance the high-temperature oxidation, corrosion, and erosion-corrosion resistance of boiler steels. In the current work, 75 pct chromium carbide-25 pct (nickel-20 pct chromium) [Cr3C2-NiCr] coating was deposited on ASTM SA213-T22 boiler steel using the HVOF thermal spray process. High-temperature oxidation, hot corrosion, and erosion-corrosion behavior of the coated and bare steel was evaluated in the air, molten salt [Na2SO4-82 pct Fe-2(SO4)(3)], and actual boiler environments under cyclic conditions. Weight-change measurements were taken at the end of each cycle. Efforts were made to formulate the kinetics of the oxidation, corrosion, and erosion-corrosion. X-ray diffraction (XRD) and field-emission scanning electron microscopy (FE-SEM)/energy dispersive spectroscopy (EDS) techniques were used to analyze the oxidation products. The coating was found to be intact and spallation free in all the environments of the study in general, whereas the bare steel suffered extensive spallation and a relatively higher rate of degradation. The coating was found to be useful to enhance the high-temperature resistance of the steel in all the three environments in this study.