Improvement in Slurry Erosion and Corrosion Resistance of Plasma-Sprayed Fly Ash Coatings for Marine Applications

Fly ash (FA), a multicompound mineral, is an industrial waste produced during coal burning in thermal power stations. It has been regarded as the most environmentally hazardous material. Furthermore, handling FA has been a significant challenge for many developing countries. Therefore, researchers have been exhorted to enhance its usage to counter its handling issues. FA is enriched with mullite, silica, and alumina. Having such mineralogy, FA can be envisaged as a promising candidate for combating erosion and corrosion in marine environments. With this motivation, the research aims to deposit as-received FA using the plasma-spraying technique onto a marine-grade steel substrate without additives and assess the performance of such coatings for erosion and corrosion properties. The coating has exhibited more than 100% improvement in microhardness. The erosion resistance was improved by similar to 11% compared to that of the uncoated sample, which is attributed to the hardness to elastic modulus ratio (H/E) and its unique mineralogy. The minor improvement in erosion resistance was attributed to the coating's poor fracture toughness. The erosion study shows that slurry concentration and rotational speeds were the most influential parameters. The scar depth was significantly shallower for FA-coated samples. The corrosion resistance has improved only by similar to 13.49%, owing to the porous nature of the coating. Therefore, such coatings with appropriate improvements in their properties are expected to assuage both environmental and industrial challenges.

Automated summary

The research aims to deposit fly ash onto a marine-grade steel substrate using plasma-spraying technique and evaluate its performance in terms of erosion and corrosion properties. The coating showed over 100% improvement in microhardness and around 11% improvement in erosion resistance, while corrosion resistance only improved by approximately 13.49% due to the porous nature of the coating.