scholarly journals High-Performance Corrosion-Resistant Materials: Iron-Based Amorphous-Metal Thermal-Spray Coatings: SAM HPCRM Program ? FY04 Annual Report ? Rev. 0 - DARPA DSO & DOE OCRWM Co-Sponsored Advanced Materials Program

2007 ◽  
Author(s):  
J Farmer ◽  
J Haslam ◽  
F Wong ◽  
S Ji ◽  
S Day ◽  
...  
Keyword(s):  
Thermal Spray ◽  
High Performance ◽  
Annual Report ◽  
Amorphous Metal ◽  
Thermal Spray Coatings ◽  
Advanced Materials ◽  
Corrosion Resistant ◽  
Spray Coatings ◽  
Iron Based

scholarly journals Corrosion Characterization of Iron-Based High-Performance Amorphous-Metal Thermal-Spray Coatings

2005 ◽  
Author(s):  
J. C. Farmer ◽  
J. J. Haslam ◽  
S. D. Day ◽  
D. J. Branagan ◽  
C. A. Blue ◽  
...  
Keyword(s):  
Corrosion Resistance ◽  
Thermal Spray ◽  
High Performance ◽  
Thermal Spray Technology ◽  
Published Data ◽  
Corrosion Resistant ◽  
Spray Coatings ◽  
Nickel Based Alloy ◽  
Iron Based

New corrosion-resistant, iron-based amorphous metals have been identified from published data or developed through combinatorial synthesis, and tested to determine their relative corrosion resistance. Many of these materials can be applied as coatings with advanced thermal spray technology. Two compositions have corrosion resistance superior to wrought nickel-based Alloy C-22 (UNS # N06022) in some very aggressive environments, including concentrated calcium-chloride brines at elevated temperature. One of these compositions, SAM1651, is discussed in detail to illustrate the promise of this general class of materials.

scholarly journals Advances in Corrosion-Resistant Thermal Spray Coatings for Renewable Energy Power Plants: Part II—Effect of Environment and Outlook

2019 ◽  
Vol 28 (8) ◽  
pp. 1789-1850 ◽  
Author(s):  
Esmaeil Sadeghi ◽  
Nicolaie Markocsan ◽  
Shrikant Joshi
Keyword(s):  
High Temperature ◽  
Thermal Spray ◽  
Power Plants ◽  
High Temperature Corrosion ◽  
Thermal Spray Coatings ◽  
Current Status ◽  
Comprehensive Overview ◽  
Biomass Waste ◽  
Corrosion Resistant ◽  
Spray Coatings

Abstract High-temperature corrosion of critical components such as water walls and superheater tubes in biomass/waste-fired boilers is a major challenge. A dense and defect-free thermal spray coating has been shown to be promising to achieve a high electrical/thermal efficiency in power plants. The field of thermal spraying and quality of coatings have been progressively evolving; therefore, a critical assessment of our understanding of the efficacy of coatings in increasingly aggressive operating environments of the power plants can be highly educative. The effects of composition and microstructure on high-temperature corrosion behavior of the coatings were discussed in the first part of the review. The present paper that is the second part of the review covers the emerging research field of performance assessment of thermal spray coatings in harsh corrosion-prone environments and provides a comprehensive overview of the underlying high-temperature corrosion mechanisms that lead to the damage of exposed coatings. The application of contemporary analytical methods for better understanding of the behavior of corrosion-resistant coatings is also discussed. A discussion based on an exhaustive review of the literature provides an unbiased commentary on the advanced accomplishments and some outstanding issues in the field that warrant further research. An assessment of the current status of the field, the gaps in the scientific understanding, and the research needs for the expansion of thermal spray coatings for high-temperature corrosion applications is also provided.

scholarly journals Optimization and Process Control for High Performance Thermal Spray Coatings

2000 ◽  
Author(s):  
Christian Moreau ◽  
Luc Leblanc
Keyword(s):  
Process Control ◽  
Thermal Spray ◽  
Plasma Spray ◽  
High Performance ◽  
Thermal Spray Coatings ◽  
Wear Resistant Coatings ◽  
Spray Coatings ◽  
Consistent Manner ◽  
The Stability ◽  
Sprayed Coatings

Abstract Thermal spray coatings are used to protect surfaces against exposure to severe conditions. To insure a reliable protection, not only the structure and properties of the sprayed coatings must be optimized but also one needs to develop appropriate process control techniques to produce high performance coatings in a consistent manner, day after day. This is particularly important during plasma spraying as the wear of the electrodes affects significantly the plasma characteristics and consequently the coating properties. First, in this paper, the stability of plasma spray processes is investigated by monitoring in-flight particle characteristics and plasma fluctuations. Secondly, the possibility and advantages of controlling plasma spray processes by monitoring and regulating the condition of the sprayed particles are discussed. Finally, we will see how the properties of thermal barrier coatings and wear resistant coatings can be optimized by controlling the temperature and velocity of the sprayed particles both in the plasma spray and HVOF (high velocity oxy-fuel) processes.

scholarly journals Advances in Corrosion-Resistant Thermal Spray Coatings for Renewable Energy Power Plants. Part I: Effect of Composition and Microstructure

2019 ◽  
Vol 28 (8) ◽  
pp. 1749-1788 ◽  
Author(s):  
Esmaeil Sadeghi ◽  
Nicolaie Markocsan ◽  
Shrikant Joshi
Keyword(s):  
High Temperature ◽  
Thermal Spray ◽  
Power Plants ◽  
Corrosion Damage ◽  
Clean Energy ◽  
High Temperature Corrosion ◽  
Thermal Spray Coatings ◽  
Corrosion Resistant ◽  
Spray Coatings ◽  
Corrosion Resistant Coatings

Abstract Power generation from renewable resources has attracted increasing attention in recent years owing to the global implementation of clean energy policies. However, such power plants suffer from severe high-temperature corrosion of critical components such as water walls and superheater tubes. The corrosion is mainly triggered by aggressive gases like HCl, H2O, etc., often in combination with alkali and metal chlorides that are produced during fuel combustion. Employment of a dense defect-free adherent coating through thermal spray techniques is a promising approach to improving the performances of components as well as their lifetimes and, thus, significantly increasing the thermal/electrical efficiency of power plants. Notwithstanding the already widespread deployment of thermal spray coatings, a few intrinsic limitations, including the presence of pores and relatively weak intersplat bonding that lead to increased corrosion susceptibility, have restricted the benefits that can be derived from these coatings. Nonetheless, the field of thermal spraying has been continuously evolving, and concomitant advances have led to progressive improvements in coating quality; hence, a periodic critical assessment of our understanding of the efficacy of coatings in mitigating corrosion damage can be highly educative. The present paper seeks to comprehensively document the current state of the art, elaborating on the recent progress in thermal spray coatings for high-temperature corrosion applications, including the alloying effects, and the role of microstructural characteristics for understanding the behavior of corrosion-resistant coatings. In particular, this review comprises a substantive discussion on high-temperature corrosion mechanisms, novel coating compositions, and a succinct comparison of the corrosion-resistant coatings produced by diverse thermal spray techniques.

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