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Development of Erosion-Corrosion-Resistant Cold-Spray Nanostructured Ni-20Cr Coating for Coal-Fired Boiler Applications

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Abstract

The erosion-corrosion (E-C) behavior of a cold-spray nanostructured Ni-20Cr coating was studied under cyclic conditions in a coal-fired boiler. This study was done for 15 cycles (1500 h), in which each cycle comprised 100 h of heating in the boiler environment, followed by 1 h of cooling under ambient air conditions. The E-C extent was evaluated in terms of thickness loss data of the samples. The eroded-corroded samples were characterized using XRD, SEM/EDS, and x-ray mapping analyses. The nanostructured coating offered excellent E-C protection to boiler tube material (SA 516 steel) under harsh live conditions of the boiler. This E-C resistance offered by investigated coating may be attributed to the presence of protective NiO and Cr2O3 phases in its oxide scale and its superior as-sprayed microhardness.

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Acknowledgment

Harpreet Singh et al. thankfully acknowledge the research grant from Department of Science and Technology, New Delhi, India (SR/S3/MERC/023/2010) for carrying out the R & D work on “Surface Engineering to Control Erosion-Corrosion of Steam Generating Plants by Nano-particle Coatings.”

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Authors and Affiliations

  1. School of Mechanical, Materials & Energy Engineering, Indian Institute of Technology Ropar, Rupnagar, Punjab, India

    M. Kumar & H. Singh

  2. Department of Chemistry, Indian Institute of Technology Ropar, Rupnagar, Punjab, India

    N. Singh

  3. International Advanced Research Centre for Powder Metallurgy & New Materials (ARCI), Hyderabad, 500005, India

    N. M. Chavan, S. Kumar & S. V. Joshi

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  1. M. Kumar
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  2. H. Singh
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  3. N. Singh
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  4. N. M. Chavan
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  5. S. Kumar
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  6. S. V. Joshi
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Correspondence to M. Kumar.

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Kumar, M., Singh, H., Singh, N. et al. Development of Erosion-Corrosion-Resistant Cold-Spray Nanostructured Ni-20Cr Coating for Coal-Fired Boiler Applications. J Therm Spray Tech 24, 1441–1449 (2015). https://doi.org/10.1007/s11666-015-0249-8

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  • DOI: https://doi.org/10.1007/s11666-015-0249-8

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