Comparison of high temperature corrosion resistance of NiCr-based coatings applied by High Velocity Oxygen Fuel and Twin Arc Spray processes

High temperature corrosion in a molten sodium sulfate salt environment is a serious problem of coal-fired boiler components. The promising possibility for surface protection is to apply thermally sprayed coatings. However, the key to success is to choose the optimal material and the proper spraying technology for a given application. Therefore, this study is aimed at a comparison of the high temperature behaviour of two protecting NiCr-based coatings sprayed by different technologies on 1.4903 (W.nr.) chrome-molybdenum steel. NiCrMoWFe was deposited by High Velocity Oxygen Fuel technology (HVOF). Twin wire arc spray technology (TWAS) was used to deposit multi-layered “multicoat” consisting of NiCrMoNbTa and NiCrTi with ceramic overlay Armaguard coated by brush. Chrome-molybdenum steel 1.7715 (W.nr.) commonly used in coal-fired boiler was also exposed to the high temperature corrosion test to evaluate the potential benefit of the coating. Coated as well as the uncoated specimens were exposed to the molten salt environment 18% Na 2 SO 4 and 82% Fe 2 (SO 4 ) 3 at 690 °C under cyclic condition. The thermogravimetric approach was used to determine kinetics of corrosion. The X-ray diffraction (XRD), scanning electron microscope (SEM) and energy dispersive spectroscopy (EDS) techniques were used to analyze the corrosion products and determine the corrosion mechanism. The results of high temperature corrosion resistance show that NiCrMoWFe coated by HVOF and multicoat sprayed by TWAS was comparable.