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The potential use of laser cladded functionally graded materials to mitigate degradation in boiler tube heat exchangers for power plant applications: a review 激光包覆功能梯度材料在电厂锅炉管换热器中的潜在用途：综述
IF 2.8 4区 材料科学
Surface Engineering Pub Date : 2023-06-03 DOI: 10.1080/02670844.2023.2249653
Joseph B. Morake, J. Mutua, MartinM . Ruthandi, E. O. Olakanmi
{"title":"The potential use of laser cladded functionally graded materials to mitigate degradation in boiler tube heat exchangers for power plant applications: a review","authors":"Joseph B. Morake, J. Mutua, MartinM . Ruthandi, E. O. Olakanmi","doi":"10.1080/02670844.2023.2249653","DOIUrl":"https://doi.org/10.1080/02670844.2023.2249653","url":null,"abstract":"ABSTRACT Surface modification is essential to safeguard heat exchangers from premature failure spurred by deterioration mechanisms such as corrosion and wear, which diminish performance. Meanwhile, modifying some substrates with dissimilar materials is challenging due to a mismatch in material properties. Moreover, individual alloy coatings on substrates are usually insufficient in the required material properties, leading to accelerated failure of equipment, especially in power plant industries. This article summarised the knowledge base on functionally graded materials (FGMs) while emphasising how this promising class of novel materials can reduce deterioration. Additionally, laser cladding is established to be a suitable technique for processing FGMs. A particular focus is laid on the laser beam interaction with the FGM and expounding on the processing and material parameters that affect the microstructural properties of FGMs. The development prospects for processing FGMs with superior clad quality characteristics to increase boiler pipes’ service life and performance are also highlighted.","PeriodicalId":21995,"journal":{"name":"Surface Engineering","volume":"39 1","pages":"677 - 721"},"PeriodicalIF":2.8,"publicationDate":"2023-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46473129","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Improving the adhesion of CrN coatings on TC4 alloy substrates by discharge current modulation in magnetron sputtering 磁控溅射中放电电流调制提高TC4合金基体上CrN涂层的附着力
4区 材料科学
Surface Engineering Pub Date : 2023-06-03 DOI: 10.1080/02670844.2023.2257359
Shuai Xu, Zhuo Zhao, Yanwen Zhou, Kaice Zhang
{"title":"Improving the adhesion of CrN coatings on TC4 alloy substrates by discharge current modulation in magnetron sputtering","authors":"Shuai Xu, Zhuo Zhao, Yanwen Zhou, Kaice Zhang","doi":"10.1080/02670844.2023.2257359","DOIUrl":"https://doi.org/10.1080/02670844.2023.2257359","url":null,"abstract":"ABSTRACTThe study reports the formation of multilayer coatings of CrN with variable gradient modulus on TC4 substrate by varying the discharge current of the hot filament in magnetron sputtering. Results show that multilayer CrN/TC4 has a higher critical failure load (63.4 N > 29.7 N), lower maximum tensile stress (103.8 GPa < 134.3 GPa), and a higher ratio of plastic to elastic deformation work (Wp/We, 2.11 > 1.58) than a single layer CrN/TC4. This indicates that the energy absorption ability of the coating/substrate before failure can be improved by increasing the loose energy-absorbing sublayer, thus improving the coating/substrate adhesion. Notably, the wear rate of both multilayer and single-layer coatings is in the order of 10−16 m3/(N·m), demonstrating their excellent wear resistance. Structural engineering enables the application of multilayer CrN coatings on low-modulus and high-strength alloy substrates, such as TC4.HIGHLIGHTS A dense-porous multilayer coating obtained by varying the filament discharge currents.The modulus difference between the multilayer CrN and TC4 reduced.The maximum tensile stress appeared at the interface of the Cr and CrN layers.The multilayer CrN/TC4 with high Wp/We and absorption ability of deformation work.The multilayer CrN/TC4 was with high adhesion and excellent wear resistance.KEYWORDS: Structure engineeringmagnetron sputteringdischarge currentsmultilayer coatingalloy substratesimulationadhesionmodulus Disclosure statementNo potential conflict of interest was reported by the author(s).Additional informationFundingThis work was supported by National Natural Science Foundation of China [grant number 51972155 and 52271056]; Foundation of Liaoning Educational Administration [grant number LJKZ0278 and LJKZ0306].","PeriodicalId":21995,"journal":{"name":"Surface Engineering","volume":"13 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135911550","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
The effect of WC-Co substrates on TiN/TiCN/Al2O3/TiCNO multilayer coatings WC-Co基体对TiN/TiCN/Al2O3/TiCNO多层涂层的影响
IF 2.8 4区 材料科学
Surface Engineering Pub Date : 2023-06-03 DOI: 10.1080/02670844.2023.2252660
Yingpu Huang, Lihui Zhu, Zhenyu Liu, Yuanyuan Bian
{"title":"The effect of WC-Co substrates on TiN/TiCN/Al2O3/TiCNO multilayer coatings","authors":"Yingpu Huang, Lihui Zhu, Zhenyu Liu, Yuanyuan Bian","doi":"10.1080/02670844.2023.2252660","DOIUrl":"https://doi.org/10.1080/02670844.2023.2252660","url":null,"abstract":"ABSTRACT In order to determine optimum substrate, TiN/TiCN/Al2O3/TiCNO coatings were deposited on WC-7Co substrate and WC-6Co substrate (named as Coating-7Co and Coating-6Co, respectively), and then the effect of WC-Co substrates on TiN/TiCN/Al2O3/TiCNO multilayer coatings was investigated by comparing the microstructure, hardness, adhesion strength, oxidation resistance and wear resistance of Coating-7Co and Coating-6Co. Results show that WC grain size of WC-6Co substrate is smaller, correspondingly the grain size of each layer in Coating-6Co is smaller, and the surface roughness is lower. Compared with Coating-7Co, Coating-6Co exhibits higher hardness, better plastic deformation capability, better oxidation resistance, lower friction coefficient and better short-period wear resistance. However, because of higher residual tensile stress and lower adhesion strength, the long-period wear resistance of Coating-6Co is worse than Coating-7Co conversely. To make good use of Coating-6Co, some post-deposition treatment techniques that can reduce residual tensile stress and improve adhesion strength should be considered.","PeriodicalId":21995,"journal":{"name":"Surface Engineering","volume":"39 1","pages":"722 - 737"},"PeriodicalIF":2.8,"publicationDate":"2023-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46590738","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Anticorrosive PEO coatings on metallic cast heat enhancers for thermal energy storage 储热用金属铸造增热剂的防腐PEO涂层
4区 材料科学
Surface Engineering Pub Date : 2023-06-03 DOI: 10.1080/02670844.2023.2236363
Natalia Raźny, Anna Dmitruk, Krzysztof Naplocha
{"title":"Anticorrosive PEO coatings on metallic cast heat enhancers for thermal energy storage","authors":"Natalia Raźny, Anna Dmitruk, Krzysztof Naplocha","doi":"10.1080/02670844.2023.2236363","DOIUrl":"https://doi.org/10.1080/02670844.2023.2236363","url":null,"abstract":"The research aims to determine whether a protective oxide coating obtained by plasma electrolytic oxidation (PEO) will prevent unfavourable changes occurring on the surface of aluminium heat enhancers for thermal energy storage (TES) based on phase change materials (PCMs). For domestic purposes (short-term, solar energy), salt hydrates are widely utilised as PCMs. Their low thermal conductivity makes the application of metal enhancers necessary to improve heat transfer in the unit. Due to the chemically aggressive nature of MgCl2·H2O, aluminium enhancers can be negatively affected during working cycles. PEO was proposed to overcome corrosion issues in the units. Cast samples, coated with PEO for a short time in KOH-Na2SiO3 electrolyte, were subjected to a molten MgCl2·H2O environment. Mass change and the surface were studied via SEM, EDS, and XRD measurements. A thin layer of aluminium oxide prevented castings from changes occurring on the surface of the enhancer.","PeriodicalId":21995,"journal":{"name":"Surface Engineering","volume":"36 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135911727","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Measurement methods and fractal dimensions of blast-cleaned steel substrates 喷砂清理钢基体的测量方法和分形维数
4区 材料科学
Surface Engineering Pub Date : 2023-06-03 DOI: 10.1080/02670844.2023.2259527
T. Marquardt, A. W. Momber, A. Krenz
{"title":"Measurement methods and fractal dimensions of blast-cleaned steel substrates","authors":"T. Marquardt, A. W. Momber, A. Krenz","doi":"10.1080/02670844.2023.2259527","DOIUrl":"https://doi.org/10.1080/02670844.2023.2259527","url":null,"abstract":"ABSTRACTMorphological parameters of steel substrates determine the adhesion of coatings and adhesives. Three different assessment methods (cross section image, contact stylus instrument, and stripe light projection) were applied to blast-cleaned substrates. A total of 12 surface configurations were generated with different abrasive materials. The fractal dimensions were estimated by means of the box-counting method. Design of experiment and ANOVA were applied to statistically analyze the relationships. Factors included abrasive type, surface preparation grade, surface roughness, and surface profile measurement method. Similar relative trends for the fractal dimensions resulted for the three measurement methods. The normalized values of the fractal dimensions were approximately twice as high for the cross section profiles compared to the ones from contact stylus and stripe light projection. Fractal values derived from contact stylus measurements showed the highest repeatability, whereas those derived from cross section images showed the lowest repeatability.KEYWORDS: Cross sectionfractal dimensionprofile impactstripe line projectionstylus instrument Disclosure statementNo potential conflict of interest was reported by the author(s).Additional informationFundingThis study received financial support from the Federal Ministry of Economic Affairs and Energy (BMWi) in Berlin, Germany, through the ‘FoKO-Wind’ project [grant number: 03EE2006A] as part of the ‘7. Energieforschungsprogramm’.","PeriodicalId":21995,"journal":{"name":"Surface Engineering","volume":"34 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134974343","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 1
Cyclic oxidation of slurry silicide-aluminide coatings formed on Ti-6Al-4V alloy Ti-6Al-4V合金表面硅铝化物浆液涂层的循环氧化研究
4区 材料科学
Surface Engineering Pub Date : 2023-06-03 DOI: 10.1080/02670844.2023.2257856
Agnieszka Kochmańska, Paweł Kochmański
{"title":"Cyclic oxidation of slurry silicide-aluminide coatings formed on Ti-6Al-4V alloy","authors":"Agnieszka Kochmańska, Paweł Kochmański","doi":"10.1080/02670844.2023.2257856","DOIUrl":"https://doi.org/10.1080/02670844.2023.2257856","url":null,"abstract":"ABSTRACT A proprietary slurry cementation method was used to produce silicide-aluminide coatings on alloy Ti-6Al-4V. The cementation processes were carried out at 900–1100 °C for 2–6 h. The coatings exhibited a stratified configuration characterised by a phase arrangement that demonstrates favourable attributes pertaining to mechanical and corrosion resistance capabilities, namely, the presence of aluminium-enriched phases at the coating surface and titanium-enriched phases proximity to the substrate. The cyclic oxidation behaviour at 800 °C for 30 twenty-two-hour cycles was investigated. The characterisation of the structure of coatings was carried out through the use of scanning microscopy, X-ray microanalysis, and X-ray diffraction techniques. The coatings have excellent resistance to cyclic oxidation, resulting from the gradient structure and the establishment of a protective alumina layer on the surface. The coatings were characterised by good resistance to thermal shocks. The microcracks formed during thermal shocks were filled with an alumina, which renders the coatings self-healing.","PeriodicalId":21995,"journal":{"name":"Surface Engineering","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135911732","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Ultra-black coatings is the new black 超黑涂料是新的黑色
IF 2.8 4区 材料科学
Surface Engineering Pub Date : 2023-06-03 DOI: 10.1080/02670844.2023.2248705
L. Gopal, T. Sudarshan
{"title":"Ultra-black coatings is the new black","authors":"L. Gopal, T. Sudarshan","doi":"10.1080/02670844.2023.2248705","DOIUrl":"https://doi.org/10.1080/02670844.2023.2248705","url":null,"abstract":"","PeriodicalId":21995,"journal":{"name":"Surface Engineering","volume":"39 1","pages":"636 - 640"},"PeriodicalIF":2.8,"publicationDate":"2023-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48927457","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Internal stress of high tungsten content Ni-W alloy coatings 高钨含量Ni-W合金镀层的内应力
4区 材料科学
Surface Engineering Pub Date : 2023-06-03 DOI: 10.1080/02670844.2023.2257855
Yingjun Xu, Deyong Wang, Minqi Sheng, Huihua Wang
{"title":"Internal stress of high tungsten content Ni-W alloy coatings","authors":"Yingjun Xu, Deyong Wang, Minqi Sheng, Huihua Wang","doi":"10.1080/02670844.2023.2257855","DOIUrl":"https://doi.org/10.1080/02670844.2023.2257855","url":null,"abstract":"ABSTRACTThis study investigates the impact of current density on the microstructure, composition, and internal stress of Ni-W alloys electrodeposited in a citrate system. Using XRD, SEM, EDS, TEM, and XPS, it was found that tungsten serves as a solute in a Ni-W FCC structure oriented in the (111) direction. Increasing current density led to higher tungsten content and current efficiency. The addition of 2-Butyne-1,4-diol altered the carbon content, significantly reducing internal stress by promoting carbide formation near grain boundaries, which prevented coating shrinkage during hydrogen escape. This carbon enrichment improved the alloy's corrosion resistance.KEYWORDS: ElectrodepositionNi-W alloyinternal stresscarbon contenthigh tungsten contentnanocrystallineAmorphous materialsElectrochemical corrosion Disclosure statementNo potential conflict of interest was reported by the author(s).Additional informationFundingThis work was supported by National Natural Science Foundation of China: [Grant Number 52174280]; Science and Technology Support Program of Jiangsu Province: [Grant Number SYG202022].","PeriodicalId":21995,"journal":{"name":"Surface Engineering","volume":"10 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135911549","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
A green vanadium-based formulation for the conversion of steel 一种绿色钒基炼钢配方
IF 2.8 4区 材料科学
Surface Engineering Pub Date : 2023-05-04 DOI: 10.1080/02670844.2023.2239027
L. Razzaboni, L. Casanova, M. Pedeferri, M. Ormellese
{"title":"A green vanadium-based formulation for the conversion of steel","authors":"L. Razzaboni, L. Casanova, M. Pedeferri, M. Ormellese","doi":"10.1080/02670844.2023.2239027","DOIUrl":"https://doi.org/10.1080/02670844.2023.2239027","url":null,"abstract":"ABSTRACT The electroless deposition of a novel vanadium-based conversion coating (VCC) on carbon steel was investigated varying parameters as vanadium salt concentration, immersion time, bath pH and temperature. The novelty resides on the deposition of a protective layer from a V4+ solution comprising green reducing agents like ascorbic and citric acids. The VCC was found to be amorphous, composed by closely packed particles rich in vanadium oxides/hydroxides. Corrosion resistance was evaluated by linear polarization resistance, Tafel extrapolation and electrochemical impedance spectroscopy. Such conversion coating provided an optimum corrosion performance for steel substrates immersed in sulphates and chlorides rich solutions. An optimum was achieved with a 0.1 M KVO3 solution held at 45°C, at pH = 3 and a deposition time of 10 min. Higher values of the latter parameters did not provide any further improvements: the formation of cracks during the dehydration process compromised the coating integrity.","PeriodicalId":21995,"journal":{"name":"Surface Engineering","volume":"39 1","pages":"613 - 624"},"PeriodicalIF":2.8,"publicationDate":"2023-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48459319","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Effect of burnishing on HVOF coated boiler steel against hot corrosion in actual boiler environment 实际锅炉环境中抛光对HVOF涂层锅炉钢热腐蚀的影响
IF 2.8 4区 材料科学
Surface Engineering Pub Date : 2023-05-04 DOI: 10.1080/02670844.2023.2242117
A. Agnihotri, S. Kalsi, H. Kansal
{"title":"Effect of burnishing on HVOF coated boiler steel against hot corrosion in actual boiler environment","authors":"A. Agnihotri, S. Kalsi, H. Kansal","doi":"10.1080/02670844.2023.2242117","DOIUrl":"https://doi.org/10.1080/02670844.2023.2242117","url":null,"abstract":"ABSTRACT Hot corrosion of boiler tubes used in steam-generating systems has been recognized as a severe problem, resulting in tube wall thinning and premature failure. In this study, the effect of burnishing the thermal sprayed coatings against high-temperature corrosion of SA213-T22 boiler steel in actual environmental conditions of coal-fired boiler has been investigated. An experimental study was carried out for ten cycles, where the individual cycle consists of one-hundred hours of exposure trailed by one hour of ambient cooling. The hot corroded specimens are visually inspected at the end of each cycle to check for any variation in colour, luster, spalling tendency, and other physical changes in scale. The tested specimens were characterized through Thermogravimetric Technique, Microhardness Tester, Optical Microscope, Scanning Electron Microscope, and X-Ray Diffractometer to study their hot corrosion performance. The findings of this work suggest that burnishing can be potentially used for providing superior hot corrosion protection to any of the thermal sprayed coated specimens.","PeriodicalId":21995,"journal":{"name":"Surface Engineering","volume":"39 1","pages":"559 - 571"},"PeriodicalIF":2.8,"publicationDate":"2023-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44447336","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
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