High-Temperature Solid-Particle Erosion Behaviour of Plasma-Sprayed Fe17Cr2Ni0.18C/Cenosphere-Based Composite Coating

Abstract

The present investigation deals to improve the solid-particle erosion resistance of boiler steel material. FeCrNiC and FeCrNiC with 5, 10 and 15wt.% cenosphere composite coatings were deposited on A387 Grade 22 steel using plasma spray technique. Powder and as-sprayed coatings are characterized using Scanning Electron Microscope (SEM), X-ray diffraction to study the surface morphology and cross section to study the nature of coatings deposited. Microhardness and adhesion strength of the coatings are evaluated. High-temperature solid-particle erosion behavior of these coating is evaluated at 300 ºC and 600 ºC at different impact angles. FeCrNiC + 15%Cenosphere designates higher hardness and adhesion strength. Convention weight change method cannot be used to validate the erosion performance due to undesirable variation. Optical profiler is used to determine erosion volume loss. The FeCrNiC coatings with the addition of cenospheres showed better erosion resistance than as-sprayed FeCrNiC and substrate. FeCrNiC + 10%Cenosphere coating shows the highest erosion resistance as compared to other coatings and substrate. Further increase in cenosphere percentage leads to reduction in erosion resistance due to predominant brittle fracture. High-temperature erosion is a concurrent erosion–oxidation process which shows combination of ductile and brittle erosion mechanism. © 2021, The Author(s), under exclusive licence to Springer Nature Switzerland AG.