Wear and Corrosion Resistances of Arc-Sprayed FeCr Alloy and Fe-Based Coatings for Boiler Heat Exchanger Pipelines

IF 3.2 3区材料科学 Q2 MATERIALS SCIENCE, COATINGS & FILMS

Journal of Thermal Spray Technology Pub Date : 2024-08-14 DOI:10.1007/s11666-024-01828-x

Wangping Wu, Sheng Lin

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Abstract

Wear and corrosion of boiler tubes in coal-based boilers are one of the serious problems. Trying to solve this issue, FeCr alloy with 45%Cr-content coating and Fe-based coating with 13%Cr-content were arc sprayed onto carbon steel substrates to enhance both the wear and corrosion resistance of boiler heat exchanger pipelines. The microstructure, chemical compositions, and phases of the coatings were analyzed using a scanning electron microscopy, energy-dispersive spectrometer, and x-ray diffraction, respectively. The wear resistance of the coatings was assessed at 25 and 300 °C using a ball-on-disk wear tester. The corrosion resistance of the coatings was evaluated based on seawater immersion, electrochemical impedance, and polarization tests. The porosities of FeCr alloy and Fe-based coatings were 4.05 and 5.75%, respectively. The microhardness values of FeCr alloy and Fe-based coatings were 377.50 ± 46.88 HV_0.5 and 666.69 ± 57.64 HV_0.5, respectively. FeCr alloy coating with lamellar structure was mainly composed of FeCr solid solution phase and a small amount of Cr oxide and Fe₃O₄ phases, and Fe-based coating was composed of a mixture phase of amorphous and crystalline, and a small amount of Fe₃O₄ phase. FeCr alloy coating had better wear resistance than Fe-based coating at both 25 and 300 °C. The wear mechanisms of the coatings were also studied. The corrosion resistance of FeCr alloy coating was better than that of Fe-based coating in corrosive solutions. Therefore, FeCr alloy coating can provide better high-temperature wear resistance and anticorrosion performance for boiler heat exchanger piping, compared with Fe-based coating.

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用于锅炉热交换器管道的电弧喷涂铁铬合金和铁基涂层的耐磨性和抗腐蚀性

燃煤锅炉管的磨损和腐蚀是严重的问题之一。为了解决这一问题，在碳钢基材上电弧喷涂了含 45%Cr 的铁铬合金涂层和含 13%Cr 的铁基涂层，以增强锅炉热交换器管道的耐磨性和耐腐蚀性。分别使用扫描电子显微镜、能量色散光谱仪和 X 射线衍射仪分析了涂层的微观结构、化学成分和相位。涂层的耐磨性是在 25 和 300 °C 温度下使用盘上球磨损测试仪进行评估的。根据海水浸泡、电化学阻抗和极化测试评估了涂层的耐腐蚀性。铁铬合金和铁基涂层的孔隙率分别为 4.05% 和 5.75%。铁铬合金和铁基涂层的显微硬度值分别为 377.50 ± 46.88 HV0.5 和 666.69 ± 57.64 HV0.5。片状结构的铁铬合金镀层主要由铁铬固溶相和少量氧化铬、Fe3O4 相组成，而铁基镀层则由非晶态和晶体混合相以及少量 Fe3O4 相组成。在 25 ℃ 和 300 ℃ 温度条件下，铁铬合金涂层的耐磨性均优于铁基涂层。此外，还研究了涂层的磨损机理。在腐蚀性溶液中，铁铬合金涂层的耐腐蚀性优于铁基涂层。因此，与铁基涂层相比，铁铬合金涂层能为锅炉热交换器管道提供更好的高温耐磨性和防腐性能。

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来源期刊

Journal of Thermal Spray Technology 工程技术-材料科学：膜

CiteScore

5.20

自引率

25.80%

发文量

198

审稿时长

2.6 months

期刊介绍： From the scientific to the practical, stay on top of advances in this fast-growing coating technology with ASM International''s Journal of Thermal Spray Technology. Critically reviewed scientific papers and engineering articles combine the best of new research with the latest applications and problem solving. A service of the ASM Thermal Spray Society (TSS), the Journal of Thermal Spray Technology covers all fundamental and practical aspects of thermal spray science, including processes, feedstock manufacture, and testing and characterization. The journal contains worldwide coverage of the latest research, products, equipment and process developments, and includes technical note case studies from real-time applications and in-depth topical reviews.