Comparative Parabolic Rate Constant and Coating Properties of Nickel, Cobalt, Iron and Metal Oxide Based Coating: A Review

Rakesh Kumar*, Santosh Kumar**
* Assistant Professor, Department of Mechanical Engineering, CGC- Chandigarh Engineering Colleges, Landran, Mohali, Punjab, India.
** Research Scholar, Department of Mechanical Engineering, IKG Punjab Technical University, Punjab, India, and Assistant Professor, Department of Mechanical Engineering, CGC- College of Engineering, Landran, Mohali, Punjab, India.
Periodicity:April - June'2018
DOI : https://doi.org/10.26634/jms.6.1.14379

Abstract

Hot corrosion is a major problem in engines, steam generators, steam turbine and thermal power plants. The coating is one of the effective methods to reduce hot corrosion. However, better understanding of the hot corrosion performance of thermal spray coating on a different substrate at different temperature and environment, is required to reduce maximum hot corrosion. This paper summarizes the behavior of Ni, Co, Fe, and metal oxide based coating in the simulated boiler environment. The consolidated results of coating properties such as coating hardness, porosity, thickness and parabolic constant has also been detailed with emphasis on corrosion and its mechanism.

Keywords

Thermal Spray Coatings, Coating Properties, Erosion-corrosion, Corrosion Mechanism, Parabolic Rate Constant.

How to Cite this Article?

Kumar, R., and Kumar, S. (2018). Comparative Parabolic Rate Constant and Coating Properties of Nickel, Cobalt, Iron and Metal Oxide Based Coating: A Review. i-manager’s Journal on Material Science, 6(1), 45-56. https://doi.org/10.26634/jms.6.1.14379

References

[1]. Bala, N., Singh, H., & Prakash, S. (2009). High temperature corrosion behavior of cold spray Ni-20Cr coating on boiler steel in molten salt environment at 900 oC. Journal of Thermal Spray Technology, 19(1-2), 110-118.
[2]. Bala, N., Singh, H., & Prakash, S. (2010). Accelerated hot corrosion studies of cold spray Ni-50Cr coating on boiler steel. Materials and Design, 31, 244-253.
[3]. Chawla, V., Chawla, A., Puri, D., Prakash, S., & Sidhu, S. B. (2011). Performance of nano-structured metal nitride coated T-22 boiler steel in Na2SO4 –60%V2 O5 environment at 900 °C under cyclic conditions. Journal of Minerals & Materials Characterization & Engineering, 10(7), 583-608.
[4]. Ebrahimifar, H., and Zandrahimi, M. (2011). Study of parabolic rate constant for coated AISI 430 steel with Mn3O4  and MnFe2O4 spinel. Indian Journal of Engineering & 2 4 Materials Sciences, 18, 314-320.
[5]. Eliaz, N., Shemesh, G., & Latanision, R. M. (2002). Hot corrosion in gas turbine components. Eng. Failure Anal., 9, 31-43.
[6]. Gonda, D., Lalbondreb, S. R., Puric, D., & Prakash, S. (2012). High temperature oxidation and hot corrosion behaviour of yttria- stabilised zirconia as plasma sprayed coating in air and salt at 900 °C under cyclic condition. Journal of Minerals & Materials Characterization & Engineering, 11(3), 285-302.
[7]. Hidalgo, V. H., Varela, F. J. B., & Rico, E. F. (1997). Erosion wear and mechanical properties of plasma-sprayed Ni and Fe based coating subjected to service condition in boiler. Trib. Int., 30, 641-649.
[8]. Hwang, Y. S., & Rapp, R. A. (1989). Thermo-chemistry and solubility of oxides in Sodium Sulfate-Vanadate solutions. Corrosion, 45(11), 933-937.
[9]. Kamal, S., Jayaganthan, R., Prakash S., & Kumar S. (2008). Hot corrosion behaviour of detonation gun-sprayed Cr C -NiCr coating on Ni and Fe based super alloys in  Na2SO4 –60%V2 O5 environment at 900 oC. Journals of Alloys  and Compounds, 463, 358-372.
[10]. Kaur, M., Singh, H., & Prakash, S. (2009). Hightemperature corrosion studies of HVOF-sprayed Cr3C2 - Ni- Cr coating on SAE-347H boiler steel. Journal of Thermal Spray Technology, 18(4), 619-632.
[11]. Kaur, M., Singh, H., & Prakash, S. (2010). Role of detonation gun spray Cr3C2 – NiCr coating in improving high  temperature corrosion resistance of SAE–213–T22 and  SAE–347H steel in presence of Na2SO4 – 82%Fe2(SO4)3 salt deposits. Surface Engineering, 26, 428-439.
[12]. Kaur, M., Singh, H., & Prakash, S. (2012). High temperature behavior of high velocity Oxy-fuel sprayed Cr3C2 - Ni-Cr coating. Journal of Metallurgical and Material Transaction, 43-A, 2979-2993.
[13]. Kaushal, G.,Singh, H., & Prakash, S. (2011). High temperature corrosion behaviour of HVOF-sprayed Ni-20Cr o coating on boiler steel in molten salt environment at 900 oC. International Journal of Surface Science and Engineering, 5(5/6), 415-433.
[14]. Khanna, A. S., & Jha, S. K. (1998). Degradation of material under hot corrosion condition. Trans. Indian Inst. Met., 51(5), 259-290.
[15]. Mishra, K. N., & Mishra, B. S. (2015). Hot corrosion performance of LVOF sprayed Al2O3 –40% TiO2 coating on superni 601 and superco 605 super alloys at 800 and 900°C. Journal of Bull. Material Science, 1-7.
[16]. Mishra, K. N., Kumar, N., & Mishra, B. S. (2014). Hot corrosion behaviour of detonation gun sprayed Al O 
40TiO2 coating on nickel based super alloys at 900°C.  Hindawi Publishing Corporation Indian Journal of Materials Science, 2014, Article ID 453607. http://dx.doi.org/ 10.1155/2014/453607
[17]. Mudgal, D., Singh, S., & Prakash, S. (2014). Evaluation of ceria-added Cr3C2 -25(NiCr) coating on three super alloys under simulated incinerator environment. Journal of Thermal Spray Technology, DOI: 10.1007/s11666-014- 0209-8, 233-242.
[18]. Natesan, K. (1976). Corrosion-erosion behavior of materials in a coal-gasification environment. 32(9), 364- 370.
[19]. Prakash, S., Puri, D., & Singh, H. (2005). Hot corrosion behaviour of plasma sprayed coating on Ni-based superalloy on Na2SO4 -60%V2O5 environment. ISIJ International, 45(6), 886-895.
[20]. Prakash, S., Singh, S., Sidhu, S. B., & Madeshina, A. (2001). Tube failure in coal fired boiler. Proc. National Seminar on Advances in Material and Processing, IITR Roorkee, India, 245-253.
[21]. Rani, A., Bala, N., & Gupta, M. C. (2017). Accelerated hot corrosion studies of D-Gun-Sprayed Cr2O3 –50% Al2O3 coating on boiler steel and Fe based super alloy. Journal of Oxid Met., DOI 10.1007/s11085-017-9759-8.
[22]. Rapp, R. A. (1986). Chemistry and electrochemistry of the hot corrosion of metals. Corrosion, 42, 568-577.
[23]. Saladi, S., Menghani, J., & Prakash, S. (2015). Effect of CeO2 on cyclic hot-corrosion behavior of detonation-gun sprayed Cr3C2 -NiCr coatings on Ni-based super alloy. Journal of Materials Engineering and Performance, 24(3), 1379-1389.
[24]. Shukla, N. V., Jayaganthan, R., & Tewari K. V. (2016). Degradation behaviour and microstructural characterization of HVOF-sprayed Cr3C2 - NiCr coatings in molten salt environment. International Journal of Materials and Product Technology, 53(1), 15-27.
[25]. Sidhu, S. B., & Prakash, S. (2002). Evaluation of the corrosion behaviour of plasma-sprayed Ni Al coatings on steel in oxidation and molten salt environments at 900°C. Surface and Coatings Technology, 166, 89-100.
[26]. Sidhu, S. B., & Prakash, S. (2006a). Studies on the behavior of Stellite-6 as plasma sprayed and laser remelted coating in molten salt environment at 900 oC under cyclic conditions. Journal of Material Science Technology, 172, 52-72.
[27]. Sidhu, S. B., & Prakash, S. (2006b). Performance of Ni- Cr alloy, Ni-Cr, Stellite-6, and Ni3Al coating in Na2SO4 -60% V2O5 environment at 900 oC under cyclic conditions. Surface and Coating Environment, 143, 1643-1644.
[28]. Sidhu, S. H., Sidhu, S. B., & Prakash, H. (2006a). Evaluation of hot corrosion behavior of LPG assisted HVOF Ni-Cr wire sprayed boiler tube steel in molten salt environment. ISIJ International, 46(10), 1067-1074.
[29]. Sidhu, S. T., Prakash, S., & Agrawal, D. R. (2006b). Characterization of HOVF sprayed Ni-Cr based coating Niand Fe based super alloy in molten salt environment. Thin Solid Film, 515, 95-105.
[30]. Sidhu, S. T., Prakash, S., & Agrawal, D. R. (2006c). Hot corrosion study of HOVF sprayed Cr3C2 Ni-Cr and Ni-20Cr coating on Nickel based super alloy at 900 oC. Surface and Coating Technology, 201, 792-800.
[31]. Sidhu, S. T., Prakash, S., & Agrawal D. R. (2006d). A comparative study of hot corrosion resistance of HVOF sprayed NiCr and Stellite-6 coated Ni based super alloy at 900 oC. Material Science and Engineering, A(445-446), 1-9.
[32]. Sidhu, S. T., Prakash, S., & Agrawal, D. R. (2006e). Hot corrosion resistance of high-velocity Oxy-fuel sprayed coatings on a Nickel-base super alloy in molten salt environment. Journal of Thermal Spray Technology, 15(3), 387-399.
[33]. Sidhu, S. T., Prakash, S., & Agrawal, D. R., (2006f). Hot corrosion behaviour of HVOF sprayed NiCr coating on Ni and Fe based super alloy in Na2SO4 -60% V2O5 environment. Acta Materialia, 54, 773-784.
[34]. Sidhu, T. S., Prakash, S., & Agrawal, R. D. (2006g). Hot corrosion and performance of Nickel-based coatings. Current Science, 90(1), 41-47.
[35]. Singh, H., Puri, D., & Prakash, S. (2005). Some studies on hot corrosion performance of plasma sprayed coating on a Fe- based super alloy. Surface & Coatings Technology, 192, 27-38.
[36]. Singh, H., Puri, D., Prakash, S., & Ghosh, K. T. (2006a). Hot corrosion of plasma sprayed Ni Al coating on a Ni 3 based super-alloy. Material and Corrosion, 58(11), 857- 965.
[37]. Singh, H., Prakash, S., Puri, D., & Phase, M. D. (2006b). Cyclic oxidation behavior of some plasma-sprayed coatings in Na2SO4 -60%V2O5environment. Journal of Materials Engineering and Performance, 15(6), 729-741.
[38]. Singh, H., Puri, D., Prakash, S., & Hira S. D. (2007). Investigations on role of plasma sprayed NiCr alloy and Ni–20Cr coatings to combat hot corrosion. Materials Science and Technology, 23(6), 736-744.
[39]. Somasundara, B., Kodali, R., & Ramesh, R. M. (2014). Hot corrosion behavior of HVOF sprayed Cr3C2 -35% Ni-Cr +5%Si coating in the presence of Na2SO4 -60%V2O5 at  700 oC. Trans. Indian Inst. Met., doi.10.1007/S12666-014- 0453-0, 1-10.
[40]. Srikanth, S., Ravikumar, B., Das, S. K., Gopalakrishna, K., Nandakumar, K., & Vijayan, P. (2003). Analysis of failures in boiler tubes due to fireside corrosion in a waste heat recovery boiler. Engineering Failure Analysis, 10, 59-66.
[41]. Wang, B., Gong, J., Wang, A. Y., Sun, C., Huang, R. F., & Wen, L. S. (2002). Oxidation behaviour of Ni-Cr coatings on Ni-based super alloy. Surface Coating Technology, 149, 70-75.

Purchase Instant Access

Single Article

North Americas,UK,
Middle East,Europe
India Rest of world
USD EUR INR USD-ROW
Pdf 35 35 200 20
Online 35 35 200 15
Pdf & Online 35 35 400 25

If you have access to this article please login to view the article or kindly login to purchase the article
Options for accessing this content:
  • If you would like institutional access to this content, please recommend the title to your librarian.
    Library Recommendation Form
  • If you already have i-manager's user account: Login above and proceed to purchase the article.
  • New Users: Please register, then proceed to purchase the article.