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International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 8, August 2017, pp. 1124–1134, Article ID: IJMET_08_08_112
Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=8
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication Scopus Indexed
EROSION BEHAVIOUR OF HVOF SPRAYED
(CR3C2-35%NICR) +5%SI COATINGS
B. Somasundaram, N. Jegadeeswaran and Madhu .G
School of Mechanical Engineering, REVA University, Bengaluru
M. R. Ramesh
Department of Mechanical Engineering, National Institute of Technology,
Karnataka, Surathkal
ABSTRACT
In the present study, (Cr3C2-35%NiCr) +5%Si cermet coatings were deposited on
a Fe based T22 steel substrate to reduce the damage caused by erosion boiler
applications. Erosion studies were conducted on uncoated as well as HVOF coated
steels. The erosion experiments were carried out using an air-jet erosion test rig
according to ASTM G-76 standard at a velocity of 30 m/s and at different
impingement angles of 30°, 60° and 90°. Silica sand particles of size ranging between
150 to180 μm were used as erodent. Analysis of weight-loss data and volumetric
steady state erosion rates for different coatings and substrate alloys are evaluated.
The bare T22 steel followed ductile erosion mode where as (Cr3C2-35%NiCr) +5%Si coating exhibited mixed behaviour respectively.
Keywords: HVOF, Solid particle erosion, Cermet’s, Surface analysis and boiler tubes.
Cite this Article: B.Somasundaram, N. Jegadeeswaran, Madhu.G and M.R.Ramesh,
Erosion Behaviour Of Hvof Sprayed (Cr3c2-35%Nicr) +5%Si Coatings, International
Journal of Mechanical Engineering and Technology 8(8), 2017, pp. 1124–1134.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=8
1. INTRODUCTION
Erosion is the progressive loss of material from a solid surface as a result of mechanical
interaction between the solid surface and a multi-component fluid or impacting solid particles
or liquid. Erosion occurs when solid particles entrained in a fluid stream (gaseous or liquid)
strike a surface [1]. Manifestations of solid particle erosion in actual service conditions
usually in the form of thinning of components, a macroscopic scooping following the gas or
particle flow, surface roughening, lack of the directional grooving characteristic of abrasion
and in some cases, the formation of ripple patterns on metal surface [2] It is generally
believed that the most erosive species in the fly ash are quartz, which is a crystalline form of
SiO2 and mullite. More than one quarter of all the boiler tube failures worldwide are caused
by fly ash erosion [3-4].
B.Somasundaram, N. Jegadeeswaran, Madhu.G and M.R.Ramesh
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Coatings provide a way of extending the limits of use of materials at the upper end of their
performance capabilities by allowing the mechanical properties of the substrate materials to
be maintained while protecting them against wear or hot corrosion [5]. The role of coating as
a corrosion barrier is similar to the role of oxide layers. The coating is protective, if it prevents
outward diffusion of metal cations and inward diffusion of elements that could react with the
substrate material. Oxide layers forming on metals in reactions with atmosphere are self-
healing to a certain extent. If the oxide layer wears of or breaks up, a new oxide layer with
almost equivalent properties will form [6].
Thermal spraying has emerged as an important tool of increasingly sophisticated, surface
engineering technology. Various properties of the coating, such as wear and hot corrosion
resistance, thermal or electrical insulation can be achieved using different coating techniques
and coating materials [7]. The term thermal spray describes a family of processes that use
chemical or electrical energy to melt (or soften) and accelerate particles of a material which is
then deposited on a surface [8]. The quality of the coatings obtained by thermal spray
techniques is related to the nature of the process and the processing parameters. On the other
hand, thermal spray coatings are a good option to repair components and prevent excessive
wear because during the deposition process no significant changes to the microstructure of
substrates or excessive deformation are promoted [9]. The principle of thermal spray is to
melt material feedstock (wire or powder), to accelerate the melt to impact on a substrate
where rapid solidification and deposit build up occurs [10].
The high-velocity oxy-fuel (HVOF) process belongs to the family of thermal spraying
techniques, and is widely used in many industries to protect the components against erosion,
corrosion and wear. Particle degradation and open porosity are the two important factors that
affect corrosion and erosion resistance. HVOF processing did not degrade significantly the
composition of the consumable and has been shown to produce coatings with low porosity,
low oxide content, better density, better coating cohesive strength and bond strength than
many thermal spray processes [11-12].
Cr₃ C₂ –NiCr and WC based thermal spray coatings using HVOF technique, appear to be
the best alternative to hard chromium plating in most cases mainly when good wear or hot
corrosion resistance is required [13]. With the HVOF spraying technique low porosity of
metallic and ceramic–metallic (cermet) coatings can be achieved, having good oxidation
resistance and adhesion properties as well as faster deposition rates compared with other spray
and coating processes [14].
Uusitalo et al. [15] and Warren [16] also suggested that coatings for combined erosion-
corrosion protection, complex formulations containing Ni, Al, Cr, Mo, Si, borides and other
minor elements may also be used. Nickel-based materials are more resistant than iron-based
materials. Chromium is considered as the most beneficial alloying element for sulfidation
resistant steels. Aluminum and silicon are also reported to increase sulfidation resistance of
steels. Depending on the partial pressures of oxygen and sulfur, oxide formers, like chromium
and silicon, may form oxides also in reducing combustion atmospheres, whereas iron and
nickel form mainly sulfides.
In the present investigation, the combination of (Cr3C2-35%NiCr) with 5%Si has been
HVOF sprayed on boiler tube steel. The deposited coatings are characterized based on
microstructures and physical properties and further evaluated for its performance under solid
particle erosion conditions.
Erosion Behaviour Of Hvof Sprayed (Cr3c2-35%Nicr) +5%Si Coatings
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2. EXPERIMENTAL PROCEDURE
2.1. Substrate Material and Development of Coating
Fe based T22 steel substrate which is used as material for boiler tubes in some coal fired
thermal power plants in northern part of India has been used as a substrate in the study. The
specimens with approximate dimensions of 30mm × 30mm ×××× 5mm were cut from the tubes for
erosion studies. Samples were grinded with SiC papers down to 180 grit and grit-blasted with
Al2O3 (Grit 45) before being HVOF sprayed to develop better adhesion between the substrate
and the coating.
The composite coating powder of (Cr3C2-35%NiCr) +5%Si was used to spray to deposit
coatings using HVOF process. HVOF spraying was carried out using a HIPOJET 2700
equipment (M/S Metallizing Equipment Co.Pvt.Ltd, Jodhpur, India), which utilize the
supersonic jet generated by the combustion of liquid petroleum gas (LPG) and oxygen
mixture. LPG fuel gas is cheap and readily available as compared to other fuels used for
HVOF spraying. The spraying parameters employed during HVOF deposition were listed in
Table 1. All the process parameters, including the spray distance were kept constant
throughout coating process.
HVOF process parameter Quantity
Oxygen flow rate 250 l/min
Fuel (LPG) flow rate 65-70 l/min
Air-flow rate 550 l/min
Spray distance 178 mm
Powder feed rate [Cr3C2-35%(NiCr)]+5%Si 28 g/min
Fuel(LPG) pressure 681 kPa
Oxygen pressure 981 kPa
Air pressure 588 kPa
Table 1 Spray parameters employed for HVOF spray process
Erodent material Silica sand
(Angular)
Erodent size (μm) 150-180
Particle velocity (m/s) 30
Erodent feed rate (gm/min) 2.2
Impact angle (°) 30,60 and 90
Test temperature Room Temperature
Test time (min) Cycles of 5 minutes
Sample Size (mm) 25 x 25 x 5
Nozzle inner diameter (mm) 1.5
Standoff distance (mm) 10
Table 2 Erosion test conditions
2.2. Erosion Studies
Room temperature erosion test was carried out using air jet erosion test rig (Figure 1) as per
ASTM G76-02 standard at P. E. S Institute of Technology, Bangalore, India. The erosion
studies were performed on uncoated as well as coated samples for the purpose of comparison.
The erosion test conditions utilized in the present study were listed in Table 2. The velocity of
B.Somasundaram, N. Jegadeeswaran, Madhu.G and M.R.Ramesh
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the eroding particles was determined by a rotating double-disc method as described by Ruff
and Ives [17]. The sample was first cleaned in acetone using an ultrasonic cleaner, dried and
then weighed using an electronic balance with least count of 0.01 mg. The sample was then
fixed to the sample holder of the erosion test rig and eroded with silica sand at the
predetermined particle feed rate, impact velocity and impact angle for a period of about 5 min.
The sample was then removed, cleaned in acetone and dried and weighed to determine the
weight loss. This weight loss normalised by the mass of the silica particles causing the weight
loss (i.e., testing time x particle feed rate) was then computed as the dimensionless
incremental erosion rate. The above procedure was repeated till the incremental erosion rate
attained a constant value independent of the mass of the erodent particles or, equivalently, of
testing time. This constant value of the incremental erosion rate was defined as the steady-
state erosion rate. The incremental erosion rate was converted into volume wear rate to take
into account the different densities of the coating material and the substrate.
Figure 1 Schematic view of an Air Jet Erosion Test Rig
3. RESULTS AND DISCUSSION
3.1. Erosion Rate as a Function of Impingement Angle
The camera photographs and schematic diagram showing the erosion scar produced on the
eroded surface at different impact angles of 30°, 60° and 90° are shown in Figure 2. The
centre portion of the eroded scar (A) represents localized region of material removal and it is
surrounded by a region of elastically loaded material (B). The loss in weight of the sample
after each 5 minutes is measured and using weight loss and mass of the erodent, erosion rate
is measured as follows
Erosion rate (g/g) = Cumulative weight loss of sample/ Mass of erodent
An erosion rate curve is drawn as a plot of erosion rate versus cumulative mass of the
erodent, for each erodent impact angle.
Steady state volume erosion rate is estimated as follows
Steady state volume erosion rate (cm3/g) = Average of constant value of incremental
erosion rate/ Density
Erosion Behaviour Of Hvof Sprayed (Cr3c2-35%Nicr) +5%Si Coatings
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Figure 2 Camera Macrographs showing the erosion scar of uncoated T22 substrate (top row, in
sequence for 30°, 60° and 90º) and (Cr3C2-35%NiCr) + 5% Si coating (Bottom row, in sequence for
30°, 60° and 90º)
Figure 3 Variation of the Incremental erosion rate with the cumulative weight of the erodent for
uncoated T22 steel at 30°, 60° and 90° impact angle
Figure 4 Variation of the Incremental erosion rate with the cumulative weight of the erodent for
(Cr3C2-35%NiCr)+5%Si coatings at 30°, 60° and 90° impact angle
B.Somasundaram, N. Jegadeeswaran, Madhu.G and M.R.Ramesh
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Figure 5 Histogram illustrating the steady state volume erosion rate of uncoated T22 steel at different
impact angles
Figure 6 Histogram illustrating the steady state volume erosion rate of (Cr3C2-35%NiCr) + 5% Si
coatings at different impact angles
The erosion rate curves along with the bar chart indicating the steady state volume erosion
rate for uncoated steel are shown in Figures 3 and 5. The steady state volume erosion rate of
the T22 steel (Figure 5) at 30° impingement is higher than that at 90° which is a characteristic
behavior of the ductile materials, where material removal takes place predominantly by plastic
deformation. This is in agreement with the study of Tabakoff [18] for Superni 718 superalloy.
It is observed that variation of erosion rate with respect to impact angle of 30°, 60° and 90º is
marginal, which indicates that the erosion rate is independent of impact angle for T22 steel.
Similar observation has been reported by Ninham [19] where erosion response of high
strength materials such as Superni 718, particularly when eroded by quartz, is weakly
dependent upon impact angle. Identical observations have been reported by Hidalgo et al. [20]
for plasma sprayed Ni-Cr coating. In general, the incremental erosion rate curves follows the
same trend as that for the ductile steels at 60° and 90°, having a low initial rate, reaching a
peak after 22 g of impacting particles and, subsequently, reaching a steady state erosion rate
which is considerably lower than the peak rate[21-22].
In the present work, the T22 substrate steel demonstrate lower erosive loss when
compared to the HVOF sprayed coatings under the same test conditions (Figure 3 and 4). The
embedment of silica particles into the substrate steel imparts the shielding effect against
further material loss. The erosion mechanism is controlled by the hardness ratio which is
defined as the ratio of hardness of the erodent particles (Hp) to the target hardness (Ht) [23-
Erosion Behaviour Of Hvof Sprayed (Cr3c2-35%Nicr) +5%Si Coatings
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26]. The silica particles have an average hardness value of 880 Hv and, for the T22 steel, it is
196 Hv. The hardness ratio Hp/Ht is approximately 4.4, which cause the penetration of silica
particles into the target material. Hutchings [27] reported that the abrasive silica particles of
any shape will embed the surface and cause plastic scratching, only if Hp/Ht>1.2.
The Scanning electron micrographs obtained on the eroded T22 (Figure 6) clearly shows
the embedment of silica sand particles into the substrate steel and the mechanism of wear is
due to indentation induced severe plastic deformation. The embedment of silica sand onto the
surface also results in variation in erosion rate with impact of cumulative mass of erodent.
Mishra et al. [28] and Sidhu hazoor singh et al. [29] also reported regarding the silica particle
embedment on the surface of eroded superalloys and steels.
It is observed from the SEM micrographs (Figure 7) of the eroded surface at 30° impact
angle that the silica sand particles deform the surface by ploughing, lip due to severe plastic
deformation of the material. With the successive impacts, these extremely strained lips are
susceptible to be detached as micro-platelets. The crater formed by ploughing and lips at the
rim of the crater are clearly seen in the micrograph. As the erodent particles are being in
contact for extended time on the surface during sliding, the mass loss is more. Similar erosion
behavior of the ductile materials has also been reported by Brown et al. [30], Kumar et al.
[31]. At 60° impact angle material damage is in the form of ploughing, groove formation and
craters. Possibly, grooves are formed due to falling off of entrapped erodent particle.
At normal impact, the substrate material undergoes severe plastic deformation and there is
less mass loss. The silica sand particles impinge onto the substrate and extrude forming a big
crater as shown in Figure 7. Small platelets are formed at the rim of the crater while the silica
eroent is extruded. These platelets are further compressed to critical plastic strain by the
impact of the subsequent erodent particles and are then detached from the rim of the crater as
micro platelets. The embedment of the silica particles into the substrate material is shown in
Figure 7. The erodent impacting at 90° will make the ductile metal to undergo work hardening
and hence the further impact of the particle will penetrate less. Thus, a ductile material at 90°
shows lower erosion rate.
3.2. Erosion Mechanism
It is known that materials that consist of both brittle and ductile constituents can behave in
either a ductile or a brittle manner, as indicated by different parameters (Levy 1986). The
erosion rate curves (Figure 4) indicates that after the initial incubation period the erosion rate
reaches a steady state in general for all the three impact angles under study. The steady state
volume erosion rate is found to be maximum for 60° impact angle (Figure 6). This suggests
that the Cr3C2-35%(NiCr) + 5% Si coatings behaves neither as ductile, where the maximum
erosion is expected at 30° nor purely brittle where maximum erosion is expected at 90° and
has a composite behavior[27], Sundararajan and Roy [32] reported the dependence of the
erosion loss on the impact angle is not a characteristic of the material alone, but also is
influenced by the erosion conditions and erodent particles and hence suggest that the terms
brittle and ductile in the context of erosion should therefore be used with caution. This leads
to the further detailed microscopic analysis.
The surface morphologies of eroded coatings at 30º and 60º impact angles (Figure 8)
shows the evidence of grooves and ridges (lips) as the material ahead of the erodent is
removed by cutting and ploughing mechanism. Also material removal may occur in the form
of platelets from the ridges around the grooves by cutting and ploughing with the repeated
impact of erodent. The groove formation in the softer binder region act as failure initiating
regions and this may also result in undercutting of the carbide grains, which may get loosened
and eventually pulled out, whereas the major mechanism of material removal is by ploughing
B.Somasundaram, N. Jegadeeswaran, Madhu.G and M.R.Ramesh
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(crater formation).The pull-out of the carbide grains (Figure 8) can also be seen in some
regions. Similar observations of carbide pull out from the WC-Co, WC-Co-Cr and Cr3C2-
20NiCr coating surface at shallow angle of impact has been reported by Hawthorne et al. [33],
Feng and ball [34].
At higher impact angle (90°), indentation impressions (Figure 8) due to the impingement
of erodent on the surface are clearly seen. The material around the grooves are generally
deformed manifest in the form of lips. The severity of deformation of the binder matrix,
dislodge the carbide particle from the surface and leads to the higher erosion loss. The impact
of erodent also damage the chromium carbide spalts, where microcracks are clearly seen. The
carbide particles as a result of propagation of cracks within it, with further impact of erodent,
are removed from the surface as fragments or chips. Thus, the surface morphology indicates
that the predominant mechanisms are grooving of binder phase, cratering, microcracks and
pull-out of carbide particles that are prevalent in the coatings. These mechanisms are
responsible for the composite erosion mode.
Figure 7 SEM micrographs showing the eroded surface morphology of T22 steel eroded at various
impact angles (a) and (b) at 30° impact angle (c) and (d) at 60° impact angle (e) and (f) at 90° impact
angle
Lip
Groove crater
Silica
particle
Platele
(a)
(c)
(e)
(b)
(d)
(f)
Erosion Behaviour Of Hvof Sprayed (Cr3c2-35%Nicr) +5%Si Coatings
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Figure 8 Surface morphology of (Cr3C2-35%NiCr) + 5% Si coated steels eroded at various impact
angles (a) and (b) at 30° impact angle (c) and (d) at 60° impact angle (e) and (f) at 90° impact angle
4. CONCLUSIONS
High velocity oxy-fuel thermal spraying with oxygen and liquid petroleum gas as the fuel
gases have been used successfully to deposit Cr3C2-35%(NiCr) + 5% Si alloy coatings on
boiler tube steels. LPG fuel gas is cheap and readily available as compared to other fuels used
for HVOF spraying.
1. The (Cr3C2-35% NiCr) + 5% Si coating material behaves neither as purely ductile nor
purely brittle as a function of impact angle and has a composite behavior whereas the
morphology of the eroded surface point out grooving of binder phase, cratering.
Platelet formation and particle pull-out that are prevalent in the coatings. The grooves
in the binder region act as failure initiating concentrators and small carbide grains
crumble off uncrushed, whereas the main mechanism of large grains failure is
chipping.
Plough
Mark
Grove
Grove
Groove
formed due to
carbide pull
Crater
Indentation
Mark
Li
p
groove
(a)
(e) (f)
(d) (c)
(b)
B.Somasundaram, N. Jegadeeswaran, Madhu.G and M.R.Ramesh
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2. Substrate T22 steel exhibit lower steady state volume erosion rate in comparison to all
the HVOF coatings under similar test conditions. The higher hardness ratio between
silica erodent particle and substrate steel might have caused the penetration of silica
particles into the surface which bestow some shielding effect against impacting
particles leading to lower wear loss.
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