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DOE OSTI · 1023492

Microstructure, Processing, Performance Relationships for High Temperature Coatings

Lillo, Thomas M
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Abstract

This work evaluates the suitability of iron aluminide coatings for use in high temperature fossil fuel combustion environments, such as boiler applications. The coatings are applied using High Velocity Oxy-Fuel (HVOF) thermal spray techniques. Iron aluminide coatings, with the nominal composition of Fe3Al, were applied to various high temperature structural materials (316 Stainless Steel, 9Cr-1Mo steel and Inconel 600) that typically lack inherent resistance to environmental degradation found in fossil fuel combustion atmospheres. Coating/substrate combinations were subjected to thermal cycling to evaluate the effect of HVOF parameters, coating thickness, substrate material and substrate surface roughness on the resistance to coating delamination and cracking. It was found that substrate surface roughness had a profound influence on the performance of a given substrate/coating system and that surface preparation techniques will need to be tailored to the specific substrate material. Also, higher particle velocity during HVOF thermal spray deposition of the iron aluminide coatings tended to result in better-performing coating/substrate systems with less delamination at the coating/substrate interface. Some combinations of HVOF parameters, coating thickness and substrate materials were found to perform extremely well even at temperatures up to 900oC. However, in some cases, substantial reactions at the interface were observed.

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20 FOSSIL-FUELED POWER PLANTS36 MATERIALS SCIENCEBOILERSBUILDING MATERIALScoating durabilityCOATINGSCOMBUSTIONDEPOSITIONFOSSIL FUELSINCONEL 600IRONiron aluminideMICROSTRUCTUREPERFORMANCEPROCESSINGROUGHNESSSTAINLESS STEELSSTEELSSUBSTRATESthermal cyclingthermal spray coatingsTHICKNESSVELOCITY

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Lillo, Thomas M. 2011-04-01. Microstructure, Processing, Performance Relationships for High Temperature Coatings. https://www.osti.gov/biblio/1023492

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