DOI: https://doi.org/10.55373/mjchem.v27i3.602

Keywords: Hot corrosion; Thermogravimetric Analysis; thermal spraying; oxide scale

Abstract

In the rigorous environment of boiler operations, corrosion harms the longevity and performance of crucial elements such as boiler tubes. To address this issue, the current work looks at the hot corrosion confrontation of Cr₂C and Ni-Cr based type of coatings applied through plasma spray in a replicated boiler environment. The coatings, which include NiCr /Al₂O₃ and Cr₂C /Al₂O₃, are applied to T22 steel substrates and extensively evaluated under circumstances that replicate the corrosive environment encountered during boiler operation. The efficiency of these coatings in preventing corrosion and maintaining the structural strength of T22 steel substrate is systematically evaluated using extensive analytical techniques such as corrosion testing, microscopy, and material characterization. The results show that NiCr and Cr₂C based coatings function well, with significant increases in corrosion resistance compared to uncoated substrates. Furthermore, the impact of composition of coating and microstructure on corrosion behaviour is examined, giving important information for the development of new corrosion-resistant materials for boiler applications. Overall, this work contributes to current efforts to improve boiler dependability, longevity, and operating efficiency by utilizing new coating methods.