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Surface & Coatings Technology 268 (2015) 153–164

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Surface & Coatings Technology


journal homepage: www.elsevier.com/locate/surfcoat

Thermally sprayed coatings resistant to erosion and corrosion for power


plant boilers - A review
Krzysztof Szymański, Adam Hernas, Grzegorz Moskal ⁎, Hanna Myalska
Silesian University of Technology, Institute of Materials Science, 40-019 Katowice, ul. Krasińskiego 8, Poland

a r t i c l e i n f o a b s t r a c t

Available online 28 October 2014 The article presents the issues related to materials and the fabrication process of protective coatings by thermal
spraying methods used for the protection of power plant boiler elements in Poland. The basic mechanisms of de-
Keywords: struction processes occurring in the fluidized bed power boilers and the associated equipment were presented.
Wear The basic methods of thermal spraying were characterized, which allow the production of coatings with the
Corrosion chemical composition, phase structure and properties appropriate for a functional performance. The advantages
Erosion
and disadvantages of the methods of thermal spraying were discussed. The basic groups of coatings with a high
Coatings
Thermal spraying
resistance to corrosion and erosion wear produced by thermal spraying methods, which can be used in the power
HVOF industry, were described.
HVAF © 2014 Elsevier B.V. All rights reserved.

1. Introduction boilers. This is connected with the intense movement of the fluidized
bed particles, which, by dropping close to the walls of the boiler, cause
The reasons for the failure of many elements of installations operat- their intense abrasion. A method use to protect the sheet pilings in the
ing in the power plant industry are the combined processes of erosion areas of intense wear is the application of protective coatings, which
and corrosion occurring at high temperatures. These processes are the assure the required operation durability. The most wear-exposed
most intense in the combustion chamber, on the surfaces of super- areas are protected with ceramic linings. An example of such areas can
heaters and economizers, as well as in the fuel and air feeding and ash be: lining of the burner area, a hump and other elements in the ash
removal systems. A scheme presenting those boiler installation ele- removal systems.
ments which are exposed to the most intense erosive–corrosive wear A special example of such protection, present in fluidized boilers, is
is shown in Fig. 1 [1–4]. the application of a ceramic lining funnel in the lower part of the
The first and basic technique of limiting the processes of erosive and chamber, and directly above the latter — thermally sprayed coatings. Un-
erosive–corrosive wear is optimization of the construction of the boiler fortunately, the use of relatively ‘thick’ ceramic linings limits the effective-
chamber and the installation elements, that is optimization of the shape ness of the heat exchange and increases the construction mass, whereas
and velocity of the dust and combustion gas stream in such a way so as the change in the geometry of the area around them causes the formation
to maximally reduce the wear of the critical elements of the boiler. An of areas of strong disturbances of the bed's flow, which lead to an intense
example of such solutions is humps in the exhaust channels, throttling damage of the walls. Such areas, if they are not detected in time, most
sheets close to the heaters, as well as modifications of the lining or often result in the machine's failure. Examples of tube damage caused
corners of the combustion chamber. by erosive and erosive–corrosive wear are presented in Fig. 2 [5].
In the places where the construction modifications do not bring The actual operation conditions present in power devices include:
good effects, certain types of materials are used, combined with the abrasive wear caused by the hard ash particles striking at various angles,
increase of their thickness, and if this is not sufficient, special pads or high operation temperature (on metal elements, it equals about 550 °C)
coatings are applied, which are made of materials with a high wear as well as corrosive operation of the fuel combustion products. This
resistance. enforces the use of such coating materials which characterize high hard-
The heatable surfaces (sheet pilings, ceilings, cofferdams) undergo a ness and good adhesion, and makes it possible to obtain their significant
very intense erosive–corrosive wear at an elevated temperature, thus thickness, low porosity and a complex phase composition guaranteeing
constituting one of the basic ‘operation problems’ present in fluidized high corrosion resistance to compounds containing sulfur, chlorine and
water steam with oxygen depletion [6–10].
⁎ Corresponding author. Among the numerous methods of protective coating production,
E-mail addresses: krzysztof.szymanski@polsl.pl (K. Szymański), adam.hernas@polsl.pl only the thermal spraying and pad welding allow the generation of
(A. Hernas), grzegorz.moskal@polsl.pl (G. Moskal), hanna.myalska@polsl.pl (H. Myalska). coatings with the abovementioned characteristics. A big advantage of

http://dx.doi.org/10.1016/j.surfcoat.2014.10.046
0257-8972/© 2014 Elsevier B.V. All rights reserved.
154 K. Szymański et al. / Surface & Coatings Technology 268 (2015) 153–164

Fig. 1. Boiler elements highly vulnerable to erosion–corrosion wear.

thermal spraying as compared to the pad welding methods is the A very important issue in the thermal spraying processes is the ap-
high speed and mobility of the process, which enables the produc- plication of appropriate coating materials. The method of producing
tion and regeneration of the coatings directly in the boilers, even at coating materials has a determining effect on the possibilities of their
the time of short standstills. The thermal spraying methods do not use for different thermal spraying technologies. For arc methods, solid
have any significant material limitations in reference to the coating or core wires are used, whereas high velocity methods use powder-
and base composition, they assure a low temperature (423 ÷ 473 K) formed materials. Producers of materials apply advanced technologies
of the treated elements and make it possible to produce coatings of which make it possible to produce materials with the assumed and
high hardness (N1500 μHV) and the thickness of the order of a few complex chemical and phase composition as well as of the specified par-
millimeters [11]. From among the many thermal spraying methods, ticle morphology. The structure of such materials is optimized for the
in practice, for the protection of boiler elements, the flame, arc, plas- given thermal spraying method and it includes the specificity of the
ma and HVOF methods are used. The flame and plasma methods are transformations taking place in the material during the process of ther-
relatively rarely used, due to the complexity of the process (flame mal spraying, formation and use of the coating.
with remelting) or the relatively high costs (plasma) [12–14]. An This is particularly essential for powder materials with an assumed
example of the interconnection between the wear mechanism, the chemical and phase composition — where a spherical shape, high den-
used spraying technology and the type of the coating material is pre- sity and a fine-grained structure are favorable. Such powders can be
sented in Table 1. produced by methods of atomization from liquid phase, agglomeration
The most often used thermal spraying method is the arc method. and sintering, as well as a mechanical and high temperature synthesis
Its biggest advantage is the possibility of effective coating of large sur- and they often undergo an additional plasma treatment. Selected coat-
faces, which is reflected in the relatively low costs of the coating pro- ing materials used for thermal spraying of coatings for the purpose of
duction. The development of the method and the high utilitarian the power industry are presented in Table 2. Examples of the morphol-
properties of the coatings result from the application of advanced com- ogy of selected powders are presented in Fig. 4.
posite materials which make it possible to obtain coatings of a de-
signed phase composition, e.g. a corrosion resistant metallic matrix
with hard reinforcement phases. A certain drawback of coatings of 2. Experimental methods
this type is their porosity, which is reduced e.g. by way of applying
high quality devices and materials as well as additional sealing coat- The intense erosion and erosion–corrosion processes present in the
ings [15,16]. lower part of fluidized boilers limit the disposability of fluidized boilers.
The most recent technology is the supersonic thermal spraying The coatings produced by different commercial companies applied at
method, which allows the production of high quality carbide coat- the end of the 1990s did not fulfill all the technical and economical
ings. The latter characterize in: high hardness (up to 1600 HV), expectations of the Polish power industry. That is why the Surface
high coating density (porosity b2%) and high adhesion (N80 MPa). Engineering Group of the Department of Materials Science of Silesian
The characteristics of the high velocity methods are a relatively broad University of Technology and the RAFAKO S.A. boiler factory was creat-
topic and it has been discussed in various publications [17,18]. Fig. 3 ed, which initiated research aiming at the development of a technically
below shows examples of coatings produced with the use of the and economically effective technology of protecting the walls of water
discussed thermal spraying methods on fragments of a boiler's sheet fluidized boilers (The Żerań and Siersza Heat and Power Stations) before
pilings. erosion or erosion–corrosion wear occurs.
K. Szymański et al. / Surface & Coatings Technology 268 (2015) 153–164 155

Fig. 2. Typical examples of erosive wear in fluidized boiler: a) the area over the ceramic lining, b) transition zone in thermally sprayed coatings, c) damage caused by erosion of the wall, and
d) damaged superheater tube.

The scope of the research implemented within the frames ■ development of material and technological concepts of water boiler
of the research projects [19–25] and the cooperated work wall protection,
included: ■ selection of technology and devices for the production of protective
coatings,
■ analysis of the causes and mechanisms of wear for selected elements ■ selection of powder and wire materials for the production of coat-
of power boilers, ings of an assumed operation durability,

Table 1
Choice of materials and technology for various operation conditions [15].

No Wear type Spraying method Material group

1. Atmospheric corrosion Flame Wires: Zn, alloys: Zn–Al, Al, Al–Mg


Powders: Al2O3, Al2O3–TiO2, CrO2
2. Arc As before + stainless steels, NiCr based alloys
3. High-temperature corrosion Flame Wires: Al., high Cr-content alloys with Ni or Fe matrix
Powders: ZrO2, ZrO2 + Y2O3, Al2O3
4. Plasma ZrO2, ZrO2 + Y2O3 modifications and other
5. Arc Al, high Cr-content alloys with Ni or Fe matrix
6. Abrasive wear Flame Powders of self-fluxing type with remelting
7. Arc Fe or Ni-based wires modified with carbide, boride, silicate phases etc.
8. HVOF Composite powders of type: WC–Co, WC–Co–Cr, NiCr–Cr3C2, WC–CrC–Ni and others
9. Abrasive–corrosive wear at elevated temperatures Arc Ni-based wires modified with carbide, boride, silicate phases etc.
10. HVOF Powders of type NiCr–Cr3C2, NiCr–Cr3C2 with modifying additions e.g.: Cr3C2–TiC–NiCr,
WC–Cr3C2–NiCr or Ni
156 K. Szymański et al. / Surface & Coatings Technology 268 (2015) 153–164

Fig. 3. Production of coatings by way of: HVOF, and arc method on elements of power boilers.

■ development of the technological parameters of the coating produc- This particularly refers to two critical areas: the one directly above the
tion, ceramic lining and the one on the wall-coating border (Fig. 2a and b).
■ determination of the basic utilitarian properties of the coatings in A similar wear character is also observed in areas where the cofferdams
laboratory tests, and the superheaters “go through” the walls of the boiler.
■ development of a technology of the production of protective coat-
ings directly on power units,
■ evaluation of the degree of wear and the durability of selected coat- 3. Results and discussion
ings under operational conditions.
Considering the wear conditions present in elements of power in-
The performed research work including the selection of materials stallations, particularly inside the power boiler, the applied protec-
and technologies of the coating production as well as the selection of tive coatings have to characterize in a dense microstructure, high
the technological parameters of the process were based on determining hardness and good erosion and corrosion resistance. Such properties
the usability of the coatings obtained in the given production variant for can be found in coatings produced by way of the HVOF and arc
the particular working conditions of the coating. The procedure is pre- methods, as well as in remelted coatings. Obtaining high quality
sented in Fig. 5. coatings, especially of a low porosity (about 1%) as well as high hard-
The realized scope of the research made it possible to develop a tech- ness requires applying high quality coating materials and good coating
nology of producing protective coatings with the use of thermal production devices as well as fulfilling all the directives of the process,
spraying methods on selected elements of power boilers. The analysis i.e. proper surface preparation, proper climatic conditions, optimal
of the information on the erosion wear occurring in Polish boilers thermal spraying parameters and appropriate final treatment of the
made it possible to select those areas of the boiler which should be coatings.
protected by way of thermal spraying as well as to select a technologi- The highest quality coatings containing carbides are obtained by the
cally and economically justified protective coating for a given area. HVOF method. Within the scope of the presented research, selected

Table 2
Typical materials used for thermal spraying of coatings on boiler elements.

Spraying method/ Name Composition/hardness Application


type of material

Arc/wires Metcoloy 5 Fe 18Cr, 8,5Mn, 5Ni, 1Si, 0.155C Austenitic steel of a lower carbon content, corrosion resistant coatings
SM 8222 Fe 28Cr, 5c, 1Mn Steel of a high content of chromium, coatings with high hardness, wear resistance and corrosion
resistance
SM 8625 Ni 21,5 Cr, 8.5Mo, 3Fe, 0.5Co High temperature creep resisting alloy with oxidation and corrosion resistance up to 1000 °C,
similar to Inconel 625
IN 625 a.b.
SM 8718 Ni 19Cr, 18Fe, 3Mo High temperature creep resisting alloy designed for regeneration of alloy Inconel 718, of high
heat resistance and corrosion resistance up to 1000 °C
W-685.1 FeCr23B3CWSiMo Designed for spraying of hard, abrasion and corrosion resistant coatings
FMI-2 FeAlCrB a.b.
HVOF WC–Co 1100–1450 Very high abrasion and erosion resistance, to be applied up to −773 K, low corrosion resistance
WC–Co–Cr 1250–1450 a.b. + very good cavitation wear resistance, good corrosion resistance in aqueous solutions
WC–CrC–Ni 1050–1350 a.b. + to be applied up to −933 K, very good corrosion resistance in aqueous solutions
Cr3C2–NiCr 800–1100 High erosion wear resistance, to be applied up to 1173 K, good tribological properties, very good
corrosion resistance in gases containing sulfur, very good corrosion resistance in aqueous
solutions
K. Szymański et al. / Surface & Coatings Technology 268 (2015) 153–164 157

Fig. 4. Powders produced by way of: a) spraying, b) agglomerating and sintering, c) mechanical alloying, and d) high temperature synthesis.

powders, presented in Table 3, were sprayed onto steel bases with the of the abrasion test performed in a T07 tester are presented in Fig. 7a.
use of the Diamond Jet 2600 system and with diversified technological High-silica sand was used as the abrasive. The erosion wear tests were
parameters of the process. The structure of the obtained coatings is performed on a research station KS-3 with a centrifugal abrasive
shown in Fig. 6. The produced coatings were evaluated not only in the ejection. Class 100 aloxite was used for the test. The results of the test
scope of the structure but also their utilitarian properties. The results are shown in Fig. 6b.

Fig. 5. Methods of assessing the structure and functional properties of coatings.


158 K. Szymański et al. / Surface & Coatings Technology 268 (2015) 153–164

Table 3 containing intermetallic phases from the Fe–Al (Table 3) system were
Carbide-containing powders used in the study. produced within the scope of the research programs implemented by
No Name of Approximate phase Granulation of the authors. The coatings, after a full cycle of tests, were used to produce
material content of powder powder [μm] test coatings in several power boilers.
1. A 558.074 WC–Co–Cr (86/10/4) −45 + 15 In special cases, other combinations of materials and protective coat-
2. A 518.074 WC–Co (88/12) −45 + 22 ing production technologies are also used. Examples of the structure of a
3. A 584.054 Cr3C2–NiCr (75/25) −45 + 10 coating sprayed from a composition of metallic and ceramic materials as
4. D 3004 Cr3C225(Ni 20Cr) −45 + 20
well as a remelted coating are presented in Fig. 11. In cases of a complex
5. D 3007 Cr3C220(Ni 20Cr) −45 + 20
6. NCC–NCT Cr3C2 25(Ni 20Cr + mod.) −45 + 15 operation of an environment degrading the material, composite coat-
ings of a laminar structure are used, where each layer plays a particular
role in the protective set. An example of a multi-layer coating is shown
in Fig. 12. A thermally sprayed coating normally has cracks as well as dif-
The very high protective properties of the coatings produced by the ferent phases of a complex shape, whereas an additional protection
HVOF method result, among others, from the very fine-grained struc- with a coating containing ceramic phases causes the formation of an
ture, which reinforces the matrix by using fine dispersive particles of additional barrier blocking the erosive operation of the environment.
nanometric sizes. Examples of such a structure are presented in Fig. 8. Production of such coatings is a complex process, yet, in some cases, it
Ultrafine-grained coatings have been tested for a few years. is technically and economically justified.
Another group of coatings used in the widely understood “power Last 10 years is an intensive development of new solutions in the
engineering” is produced by the method of arc thermal spraying. field of thermal sprayed coatings for energy applications in Poland.
Those are metallic coatings characterizing in a band structure with the The main part of the research is carried out at the Silesian University
porosity of the order of up to a few percent (it is beneficial for the poros- of Technology in the Team of Surface Engineering. This development en-
ity to be as low as possible due to the operation in an aggressive corro- compasses both new technologies as well as coating-forming materials.
sive atmosphere). The latter is most significantly affected by the proper In the case of new technologies of thermal spraying the high velocity
selection of material, device and technological parameters of the coating air fuel method is becoming more widely used as a method to obtain the
production. It is possible to obtain coatings with low porosity (about 1%) coatings with significantly lower porosity, higher hardness and service
and high thickness (0, 5–1 mm) as well as diversified hardness — from life [26]. A higher level of sprayed particle's speed and its lower temper-
350 (IN635) to over 1000–1200 HV (e.g. W-685 and CE-595). Such ature give a possibility to obtain coatings with a much lower level of un-
diversified properties of the coatings can be obtained by way of applying desirable phase, typical for high velocity oxy fuel process. Typical phases
materials of different chemical and phase compositions as well as opti- constituent of HFAV and HFOF coatings are showed in Fig. 13.
mized parameters of the coating production. Examples of wire materials Another direction of coating's development is modification of
used in the application of this type are shown in Table 3. existed solution. One of the best is modification of FeAlCrB coating-
A properly conducted thermal spraying process in combination with forming materials from versions FMI-2 to FMI-3 with a higher level of
an appropriate preparation of the base makes it possible to obtain thick, aluminum [27] (Table 4). This type of coating is operated successfully
well adhering coatings with high utilitarian properties. Examples of the for 13 years, and periodic repairs still showed the satisfactory condition
structure of the produced coatings are shown in Fig. 9, whereas the of the coating. The top surface of covered pipes is showed in Fig. 14. The
results for the erosion resistance can be found in Fig. 10. Materials same situation was observed in the case of WC–Co coatings obtained by

Fig. 6. Microstructure of carbide-containing coatings thermally sprayed by HVOF: a) type of WC–Co–Cr, b) WC–Co, c) Cr3C2–NiCr, and d) and flame Cr3C 27 (Ni20Cr) (430 NS).
K. Szymański et al. / Surface & Coatings Technology 268 (2015) 153–164 159

Fig. 7. Abrasion wear resistance a) and erosion resistance b) for HVOF sprayed coatings of materials containing carbides.

Fig. 8. Structure of coatings HVOF-sprayed to submicron particle sizes.


160 K. Szymański et al. / Surface & Coatings Technology 268 (2015) 153–164

Fig. 9. Structure of arc-sprayed coatings of: a) FMI-3, b) W-685, c) 27 DS, and d) CE-595.

HVOF method and additionally modified by TiC addition. Comparative study of phases constituent of WC–Co + TiC coating, which demon-
studies of the standard and modified coatings in real operating condi- strated the formation of a phase-type Co2C and Co3Ti at the expense of
tions showed a much better state of the coating with the addition of undesirable phases W2C, WC1 − x, Co3W9C4 and Co6W6C [28].
TiC particles. It was also found that the hardness of the coating modified The next used method is based on the bi-modal microstructure of
slowly, but steadily increases with increasing operating time, as wad re- coating creation to increase their durability. In this case chemical and
vealed during periodic shutdowns of boiler. This suggests that the slow- phase composition of coatings can be changed as well. Those types of
down of creation of undesirable phase triple type W–Co–C by the solution were not yet verified under operational conditions, but they
addition of just TiC takes place. This has been confirmed in a preliminary are under intensive investigations by the Surface Engineering Team of

Fig. 10. Erosive wear resistance of arc-sprayed coatings.


K. Szymański et al. / Surface & Coatings Technology 268 (2015) 153–164 161

Fig. 11. Structure of a coating formed from ceramic materials by flame atomic absorption and a coating with an additional remelting process.

Silesian University of Technology. The study shall be subject to the type of 8YSZ, for example pyrochlore of zirconate, ceriate and hafniate types
coating WC–Co with the addition of nano-sized powders of WC, TiC, Cr3C2 [29]. From the other sites conceptions of two layered coatings of DCL
and B4C. The results of the initial investigations published for TiC addi- (double ceramic layer) type are expanded [30].
tions in position [26] and for other modifiers revealed that 5 wt.% of mod-
ified addition improved hardness deposited by HVAF method coatings.
The last important direction of coating investigations related to their 4. Conclusions
power plant's applications (and for aircraft turbines as well) is the
ceramic coating of TBC (thermal barrier coating) type. In this case the Thermal spraying technologies allow production of complex coat-
investigations are concentrated on new types of materials, other than ings on practically all kinds of metallic surfaces by way of applying

Fig. 12. Multi-layered structure of thermally sprayed coatings.


162 K. Szymański et al. / Surface & Coatings Technology 268 (2015) 153–164

Fig. 13. Diffractograph of the coating deposited with the HVOF a), and HVAF b) technique.

Table 4 various special coating materials. These coatings characterized in a set of


Wires used in the study. beneficial utilitarian properties, include:
No Name of material Approximate phase
composition of powder • high corrosion resistance, also at high temperatures,
• high erosion resistance, also at elevated temperatures,
1. FMI — 3 FeAlCrB
2. W — 685 Fe–Cr–B • option of regeneration of the coatings at the locations of their use.
3. M5 Fe–Cr–C
4. SF 27 Fe–Ni–Cr–Si–B These properties allow their wide use in the protection of power
5. NGK WC–Cr–Co boiler elements. The effectiveness of the protection results from the ap-
6. FMI — 2 B Fe–Al–Cr–B
plication of appropriate high quality coating materials, advanced coat-
7. CE — 595 Fe–Cr–Si–B
ing production technologies and high experience of the companies
K. Szymański et al. / Surface & Coatings Technology 268 (2015) 153–164 163

Fig. 15. Protective coatings in a fluidized-bed power boiler: after 1 year of operation, the
process of regeneration of the coating and the area regenerated after 9 years of service.
Fig. 14. Top surface of FMI-3 coating after 13 years period of exposure.

which provide such services. In Fig. 15, it can see surfaces protected with [4] B.Q. Wang, Wear 199 (1996) 24–32.
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[19] Project — KBN 4 T08C 008 25 pt: “Kompozytowe materiały i powłoki natryskiwane
Programme — Advanced technologies for energy generation: develop- cieplnie metodami naddźwiękowymi — HVOF i HVAF o wysokiej odporności na
ment of a technology for highly efficient zero-emission coal-fired zużycie korozyjne i erozyjne” (Composites materials and coatings thermally
power units integrated with CO2 capture. sprayed by high velocity methods of HVOV and HVAF type with high resistance to
corrosion and erosion wear).
[20] Project — COST 522 — “Development of new materials with high dispersion inter-
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