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Effect of Structure Density of Milled Powder on Hot Corrosion and Erosion Resistance of HVOF-Sprayed Cr3C2-NiCr Coating

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Abstract

The present study investigated the effect of mechanical milling on Cr3C2-NiCr coatings deposited using the HVOF spraying method. The milling process was carried out using powder with varying characteristics to produce fine-grained and flaky powders. The milled powder coatings exhibited higher density and reduce porosity, leading to improve surface hardness and bond strength. To evaluate the performance of these coatings, hot corrosion and erosion tests were conducted under controlled conditions. The hot corrosion test was performed in a chloride environment using a vapor-condensed salt mixture (45% NaCl + 55% KCl) at 600 °C for 100 hours, while the erosion test was conducted at room temperature with an impact angle of 90°. The results showed that the milled powder coating demonstrated superior resistance to both corrosion and erosion compared to the unmilled powder coating. Specifically, the corrosion mass product and erosion rate of the milled powder coating were 3.40 mg/cm2 and 0.62 mg/g, respectively, while those of the unmilled powder were 10.07 mg/cm2 and 1.84 mg/g, respectively. This study revealed that the microstructure of powder coating has a significant effect on its erosion and hot corrosion performance. Furthermore, the research investigated the mechanisms responsible for these performances and concluded that the coating’s porosity and homogeneous structure can enhance its resistance against both erosion and corrosion.

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Acknowledgment

The authors would like to thank to collaborative research project between National Research and Innovation Agency (BRIN) and PT. Pembangkitan Jawa Bali (PJB) with contract No. 409.SPK/061/BMUM/2021 and National Research and Innovation Agency (BRIN) with contract No. 3/III.10/HK/2023 for supporting the present research work.

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  1. Department of Physics, Faculty of Mathematics and Natural Science, University of Indonesia, Jl. Margonda Raya, Depok, 16424, Indonesia

    Safitry Ramandhany & Djoko Triyono

  2. Research Center for Advanced Materials, National Research and Innovation Agency (BRIN), Kawasan Puspiptek, Serpong, 15314, Indonesia

    Safitry Ramandhany, Eni Sugiarti, Agus Sukarto Wismogroho, Hubby Izzuddin, Ahmad Afandi, Wahyu Bambang Widayatno, Resetiana Dwi Desiati & Risma Y. Sundawa

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Ramandhany, S., Triyono, D., Sugiarti, E. et al. Effect of Structure Density of Milled Powder on Hot Corrosion and Erosion Resistance of HVOF-Sprayed Cr3C2-NiCr Coating. J Therm Spray Tech 33, 1075–1099 (2024). https://doi.org/10.1007/s11666-024-01720-8

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