Abstract
The present work investigates the hot corrosion behaviour of CNT-reinforced zirconium yttrium coatings on T-91 boiler tube steel in a molten salt (Na2SO4–60 wt%V2O5) environment at 600 °C under cyclic conditions. Air plasma spray technique was used for the development of coatings. The un-coated coated and all the as-coated specimens were subjected to hot corrosion exposure in a silicon tube furnace at 600 °C for 50 cycles. The corrosion behaviour was examined through mass gain measurements after the completion of each cycle. The corroded product was examined by XRD and SEM with EDAX analysis. After critical examination it was concluded that the oxide scale of Fe2O3 was formed on un-coated specimen as a result of it suffered from thermal spallation. All the as-coated specimens show the lower mass gains with good adhesiveness of oxide scale with the substrate steel. The CNT-reinforced zirconium yttrium coatings was found to provide better corrosion resistance in the hot corrosion environment due to uniform dispersion of CNT in the coatings matrix and the formation of protective zirconium oxide in the scale.
Similar content being viewed by others
References
Duarte CA, Espejo E, Martinez JC (2017) Failure analysis of the wall tubes of a water-tube boiler. Eng Fail Anal 79(January):704–713. https://doi.org/10.1016/j.engfailanal.2017.05.032
Alia FF et al (2017) High temperature oxidation in boiler environment of chromized steel. IOP Conf Ser. https://doi.org/10.1088/1757-899X/257/1/012086
Kumar D, Pandey KN, Das DK (2016) Microstructure studies of air-plasma-spray-deposited CoNiCrAlY coatings before and after thermal cyclic loading for high-temperature application. Int J Miner Metall Mater 23(8):934–942. https://doi.org/10.1007/s12613-016-1309-x
Ding Q, Tang X, Yang Z (2017) Failure analysis on abnormal corrosion of economizer tubes in a waste heat boiler. Eng Fail Anal 73:129–138. https://doi.org/10.1016/j.engfailanal.2016.12.011
Keyvani A, Bahamirian M (2016) Oxidation resistance of Al2O3 -nanostructured/CSZ composite compared to conventional CSZ and YSZ thermal barrier coatings. Mater Res Express 3(10):1–12
Loghman-estarki MR, Nejati M, Edris H, Shoja R (2016) Comparison of hot corrosion behavior of nanostructured ScYSZ and YSZ thermal barrier coatings in the presence of molten sulfate and vanadate salt Evaluation of hot corrosion behavior of plasma sprayed scandia and yttria co-stabilized nanostructured therma. J Eur Ceram Soc 35(2):693–702. https://doi.org/10.1016/j.jeurceramsoc.2014.08.029
Goyal K, Goyal R (2019) Improving hot corrosion resistance of Cr3C2–20NiCr coatings with CNT reinforcements. Surf Eng. https://doi.org/10.1080/02670844.2019.1662645
Jiang C, Xing Y, Zhang F, Hao J (2012) Microstructure and corrosion resistance of Fe/Mo composite amorphous coatings prepared by air plasma spraying. Int J Miner Metall Mater 19(7):657–662. https://doi.org/10.1007/s12613-012-0609-z
Saladi S, Menghani J, Prakash S (2014) Hot corrosion behaviour of detonation-gun sprayed Cr3C2–NiCr coating on Inconel-718 in molten salt environment at 900 °C. Trans Indian Inst Metals 67:623–627. https://doi.org/10.1007/s12666-014-0383-x
Huang L, Meng H, Liang L, Li S, Shi J (2015) Effects of heat treatment on the corrosion resistance of carbon steel coated with LaMgAl11O19 thermal barrier coatings. Int J Miner Metall Mater 22(10):1050–1059. https://doi.org/10.1007/s12613-015-1167-y
Pal V, Sidhu S, Goyal K (2017) Comparative study of corrosion behaviour of HVOF-coated boiler steel in actual boiler environment of a thermal power plant. J Austral Ceram Soc. https://doi.org/10.1007/s41779-017-0107-x
Bengtsson P, Johannesson T (1995) Characterization of microstructural defects in plasma-sprayed thermal barrier coatings. J Therm Spray Technol 4(3):245–251. https://doi.org/10.1007/BF02646967
Fargas G, Casellas D, Llanes L, Anglada M (2003) Thermal shock resistance of yttria-stabilized zirconia with Palmqvist indentation cracks. J Eur Ceram Soc 23(1):107–114. https://doi.org/10.1016/S0955-2219(02)00065-1
Saremi M, Afrasiabi A, Kobayashi A (2007) Bond coat oxidation and hot corrosion behavior of plasma sprayed YSZ coating on Ni superalloy. Trans JWRI. 36(1):41–45
Tianshun D, Xiukai Z, Guolu L, Li L, Ran W (2018) Microstructure and corrosive wear resistance of plasma sprayed Ni-based coatings after TIG remelting. Mater Res Express 5(2):026411
Fukanuma H (1994) A porosity formation and flattening model of an impinging molten particle in thermal spray coatings. J Thermal Spray Technol 3(1):33–44
Chatha SS, Sidhu HS, Sidhu BS (2012) Characterisation and corrosion-erosion behaviour of carbide based thermal spray coatings. J Miner Mater Charact Eng 11(06):569–586. https://doi.org/10.4236/jmmce.2012.116041
Kamal S, Jayaganthan R, Prakash S (2009) Evaluation of cyclic hot corrosion behaviour of detonation gun sprayed Cr3C2-25%NiCr coatings on nickel- and iron-based superalloys. Surf Coatings Technol 203(8):1004–1013. https://doi.org/10.1016/j.surfcoat.2008.09.031
Sapundjiev D, Van Dyck S, Bogaerts W (2006) Liquid metal corrosion of T91 and A316L materials in Pb–Bi eutectic at temperatures 400–600 °C. Corrosion Sci 48(3):577–594. https://doi.org/10.1016/j.corsci.2005.04.001
Goyal R, Sidhu BS, Chawla V (2018) Oxidation behaviour of plasma sprayed carbon nanotubes-alumina coated ASME-SA213-T291 boiler tube steel. J Mater Metall Eng 7(3):1–15
Goyal K, Singh H, Bhatia R (2019) Hot-corrosion behavior of Cr2O3-CNT-coated ASTM-SA213-T22 steel in a molten salt environment at 700 °C. Int J Miner Metall Mater 26(3):337–344
Singh S, Goyal K, Goyal R (2016) Performance of Cr3C2-25 (Ni–20Cr) and Ni–20Cr coatings on T22 boiler tube steel in simulated boiler environment. J Thin Films Coat Sci Technol Appl 3(2):19–26
Goyal K, Singh H, Bhatia R (2019) Hot-corrosion behavior of Cr2O3-CNT-coated ASTM-SA213-T22 steel in a molten salt environment at 700°C. Int J Miner Metall Mater 26(3):337–344. https://doi.org/10.1007/s12613-019-1742-8
Keshri AK, Agarwal A (2011) Splat morphology of plasma sprayed aluminum oxide reinforced with carbon nanotubes: a comparison between experiments and simulation. Surf Coatings Technol 206(2–3):338–347. https://doi.org/10.1016/j.surfcoat.2011.07.025
Sidhu VPS, Goyal K, Goyal R (2017) Comparative study of corrosion behaviour of HVOF-coated boiler steel in actual boiler environment of a thermal power plant. J Aust Ceram Soc 53(2):925–932. https://doi.org/10.1007/s41779-017-0107-x
Thakare JG, Pandey C, Mulik RS, Mahapatra MM (2018) Mechanical property evaluation of carbon nanotubes reinforced plasma sprayed YSZ-alumina composite coating. Ceram Int 44(6):6980–6989
Prasanna PA, Sreenivasulu PSV (2018) High-temperature corrosion behaviour of HVOF sprayed Cr3C2–25NiCr coated on alloy X22CrMoV12–1 at 600 °C. J Therm Spray Eng 1(1):7–12
Sharma V, Kumar S, Kumar M, Deepak D (2019) High temperature oxidation performance of Ni-Cr-Ti and Ni-5Al coatings. Mater Today Proc. https://doi.org/10.1016/j.matpr.2019.11.048
Gond D et al (2010) Oxidation studies of T-91 and T-22 boiler steels in air at 900 °C. J Miner Mater Charac Eng 9(8):749–761
Meng X, Tan X, Meng B, Yang N, Ma ZF (2008) Preparation and characterization of yttria-stabilized zirconia nanotubes. Mater Chem Phys 111(2–3):275–278. https://doi.org/10.1016/j.matchemphys.2008.04.017
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
Authors declare that they have no conflicts of interest of any sort.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Kumar, S., Bhatia, R. & Singh, H. Hot Corrosion Behaviour of CNT Reinforced Zirconium Yttrium Coatings in Molten Salt Environment. J Bio Tribo Corros 6, 81 (2020). https://doi.org/10.1007/s40735-020-00378-3
Received:
Revised:
Accepted:
Published:
DOI: https://doi.org/10.1007/s40735-020-00378-3