Search results

In Indian thermal power plants, the main cause of boiler tube failure is the presence of molten sulphates and vanadates, which deteriorate the tube material at high temperatures. To combat the hot corrosion failure of metals, thermal spray technology is adopted. This study aims to investigate and study the effect of hot corrosion behaviour of carbon nanotube (CNT)-reinforced ZrO₂-Y₂O₃ composite coatings on T-91 boiler tube steel in a molten salt environment at 900 °C for 50 cycles.

A plasma spray technique was used for development of the coatings. The samples were exposed to hot corrosion in a silicon tube furnace at 900 °C for 50 cycles. After testing, the test coupons were analysed by X-ray diffraction, scanning electron microscopy/energy dispersive spectroscopy and cross-sectional analysis techniques to aid understanding the kinetics of the corrosion reaction.

CNT-based reinforced coatings showed lower weight gain along with the formation of protective oxide scales during the experimentation. Improvement in protection against hot corrosion was observed with increase in CNT content in the coating matrix.

It is pertinent to mention here that the high temperature behaviour of CNT-reinforced ZrO₂-Y₂O₃ composite on T-91 steel at 900°C temperature in molten salt environment has never been studied. Thus, the present research was conducted to provide useful results for the application of CNT-reinforced composite coatings at elevated temperature.

Molten sulphate-vanadate induced hot corrosion is the main reason of failure of boiler tubes used at high temperatures in thermal power plants. The hot corrosion can be encountered by applying thermal spray coatings on the alloy steels. In this perspective, this paper aims to attempt to investigate the effect of carbon nanotubes reinforcement on Cr₂O₃ composite coatings on hot corrosion behaviour of ASTM-SA213-T22 steel in a corrosive environment of Na₂SO₄ – 60%V₂O₅ at 900^°C for 50 cycles.

The coatings have been deposited with high velocity oxy fuel process. The samples were exposed to hot corrosion in a Silicon tube furnace at 900^°C for 50 cycles. The kinetics of corrosion behaviour were analysed by the weight gain measurements after each cycle. Corrosion products were analysed with X-ray diffraction, scanning electron microscopy, energy dispersive and cross-sectional analysis techniques.

During investigations, the carbon nanotubes (CNT) reinforced Cr₂O₃ composite coatings on T22 steel were found to provide better corrosion resistance in the molten salt environment at 900^°C. The coatings showed lower weight gain along with formation of protective oxide scales during the experiment. Improvement in protection against hot corrosion was observed with increase in CNT content in the coating matrix.

The addition of CNT has resulted in reduction in porosity by filling the voids in chromium oxide coating, with interlocking of particle and has blocked the penetration of corroding species to enhance the corrosion resistance of the composite coatings. The corrosion rate was found to be decreasing with increase in CNT content in coating matrix.

It must be mentioned here that high temperature corrosion behaviour of thermally sprayed CNT-Cr₂O₃ composite coatings has never been studied, and it is not available in the literature. Hence, present investigation can provide valuable information for application of CNT-reinforced coatings in high temperature fuel combustion environments.

The purpose of this study was to fabricate carbon nanotubes (CNT)-reinforced chromium oxide coatings and investigate mechanical and microstructural properties of these newly developed coatings on the boiler tube steel.

1 and 4 Wt.% CNT-reinforced Cr₂O₃ composite coatings were prepared and successfully deposited on ASTM-SA213-T22 (T22) boiler tube steel substrates using high-velocity oxy fuel (HVOF) thermal spraying method. Microhardness, porosity, metallography, X-ray diffraction (XRD), scanning electron microscopy (SEM)/energy-dispersive X-ray spectroscopy, cross-sectional elemental analysis and X-ray mapping analysis have been used to examine the coated specimens.

The porosity of the CNT-Cr₂O₃ composite coatings was found to be decreasing with the increases in CNT content, and hardness has been found to be increasing with increase in percentage of CNT in the composite coatings. The CNT were able to increase hardness by approximately 17 per cent. It was found that the CNT were uniformly distributed throughout Cr₂O₃ matrix. The CNT were found to be chemically inert during the spraying process.

It must be mentioned here that studies related to fabrication of HVOF sprayed CNT reinforced Cr₂O₃ composite coatings on T22 boiler tube steel are not available in the literature. Hence, present investigation can provide valuable information related to fabrication and properties of CNT reinforced coatings on boiler steel.