Accelerated hot corrosion studies of cold spray Ni–50Cr coating on boiler steels

In the current investigation Ni–50Cr powder was deposited on two boiler steels SA-213-T22 and SA 516 (Grade 70) by cold spray process. The hot corrosion performance of coated as well as bare boiler steels was evaluated in an aggressive environment of Na2SO4–60% V2O5 under cyclic conditions at an elevated temperature of 900 °C. The kinetics of the corrosion was approximated by the weight change measurements made after each cycle for a total period of 50 cycles. Each cycle consisted of 1 h heating in a tube furnace followed by 20 min cooling in ambient air. X-ray diffraction (XRD), scanning electron microscopy/energy dispersive X-ray analysis (SEM/EDAX) techniques were used to analyse the corrosion products. Both the uncoated boiler steels suffered intensive spallation in the form of removal of their oxide scales, which may be attributed to the formation of unprotective Fe2O3 dominated oxide scales. The Ni–50Cr coated steels showed lesser weight gains and the oxide scales remained intact till the end of the experiment. The phases revealed in the oxide scales of the coated specimens were mainly oxides of chromium and nickel and their spinels which are reported to be protective against the hot corrosion.