Coatings for High-Temperature Environments: Anti-Corrosion and Anti-Wear Applications (Engineering Materials)

Description

This book addresses the recent trends in high-temperature coatings that are used to provide oxidation and wear resistance to metallic/ceramic components in extreme environments. Ceramics, intermetallics, organosilicon polymers, cermets, and other materials with great thermal stability have long been recognized for these applications. This book introduces the state of the art in coating materials and processes for high-temperature environments and identifies areas for improvement in materials selection, performance upgrades, design considerations, and manufacturing methods. The book covers a variety of high-temperature coatings prepared through various synthesis processes such as thermal spraying, physical vapor deposition, electrodeposition, and sol–gel methods. It covers corrosion/oxidation, phase stability, and thermal and mechanical behavior of high-temperature coating materials having greater thermal stability. With contributions from international researchers active in the field, this edited book features the most recent and up-to-date literature references for a broad readership consisting of academic and industrial professionals. It is suitable for graduate students as well as scientists and engineers working in the area of anti-corrosion and anti-wear resistant high-temperature coatings for industrial applications. Preface Acknowledgements About This Book Contents Corrosion Resistant Coatings for High Temperature Environment Corrosion Under Insulation for Hot Structural Components 1 Introduction 2 Case Studies of Corrosion Under Insulation (CUI) 3 Fundamental Concepts of Corrosion and CUI 3.1 Environmental Factors 3.2 Other Factors 3.3 On-Site Non-destructive Testing (NDT) Methods for CUI 4 Concepts and Methods for CUI Protection 4.1 Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) 4.2 Modified Thermal Insulation Structures 4.3 Anti-CUI Coatings 5 Materials of Anti-CUI Coatings 5.1 Polymer Coatings 5.2 Metallic Pigment Coatings 6 Standardization Laboratory Test for Anti-CUI Coatings 6.1 ASTM G189-07(2021) 6.2 ISO 19277:2018 7 Summary References Development of Coating-Resistant Materials at High Temperatures for Waste-to-Energy Plant Application 1 Introduction 1.1 WTE Boiler Corrosion Environment 2 HTC-Resistant Materials and Coatings Technological Advances 2.1 CRCs for WWTs 2.2 Alloy Tubes with Corrosion Resistance and Superheater Coatings 3 Materials and Coatings Corrosion Mechanisms 3.1 Resources Corrosion Mechanisms 3.2 Spray Coatings Deterioration Mechanisms 4 Corrosion-Resistant Substances and Coatings: Application Trends 4.1 Coatings for Waterwall Tubes 4.2 Superheaters Corrosion‐Resistant Alloys and Coatings 5 Decline Mechanisms and Design of Coatings 5.1 Formation and Breakdown of Protective Oxides Layer 5.2 Erosion and Erosion/Corrosion-Resistant Materials and Coatings 5.3 Durability of Alloy and Ceramic Spray Coatings 6 Conclusion References Composite Enamel Coatings for Thermal Shock and Chloride Corrosion Coupled Environments 1 Introduction 2 Surface and Microstructural Characterization of Composite Enamel Coatings 2.1 Silicon Nitride/Enamel Composite Coatings 2.2 Silicon Carbide/Enamel Composite Coatings 2.3 Enamel/Steel Interface Analysis 3 Mechanical Properties of Composite Enamel Coatings 3.1 Strength of Coated Steel 3.2 Adhesion of Coating to Steel Substrate 3.3 Hardness and Indentation Cracking Resistance 3.4 Impact Resistance 4 Thermal Shock Resistance of Composite Enamel Coatings 4.1 Thermal Shock Damages 4.2 Dilatometric Analysis 4.3 Residual Stress Analysis 4.4 Microstructure-Dependent Thermal Shock Resistance 5 Corrosion Resistance of Composite Enamel Coatings 5.1 Corrosion Morphology Evolution 5.2 Electrochemical Study 5.3 Salt-Spray Test 5.4 Corrosion Evolution Mechanism 6 Summary References Polycrystalline Diamond and Cr Double Coatings Protect Zr Nuclear Fuel Tubes Against Accidental Temperature Corrosion in Water-Cooled Nuclear Reactors 1 Introduction 2 PCD Coating on ZIRLO Substrate: History of Application 3 Growth of PCD Layer on ZIRLO Substrate 4 Cr Coating on ZIRLO Substrate 5 Hot Steam Oxidation 5.1 Hot Steam Oxidation of PCD-Coated ZIRLO 5.2 Corrosion of ZIRLO Coated by Magnetron-Sputtered Cr 5.3 Hot Steam Oxidation of PCD and Cr-Coated ZIRLO 6 Summary References Silicon-Based Technologies for High-Temperature Coatings and Their Corrosion Behaviours 1 Introduction 2 Types of Silicon-Based Coating 2.1 Protective Coating 2.2 Conductive Coating 2.3 Bond Coating 2.4 Dip Coating 2.5 Spin Coating 2.6 Spray Coating 2.7 Preceramic Polymers 2.8 Particle-Filled Coatings 3 Properties of Coating 3.1 Permeability 3.2 Adhesion 4 Mechanisms of Adhesion 5 Properties of Silicon-Based Technology and Their Application 5.1 Primers 5.2 Heat-Resistant Coatings 5.3 Industrial Maintenance Coatings 5.4 Hygienic Coatings 5.5 Abrasion-Resistant Coatings 6 Benefits of Silicon-Based Additives 7 High-Temperature Corrosion-Resistant Ceramic Coating 8 Corrosion-Resistant Coatings for High-Temperature Applications 9 Conclusions and Future Outlook References High Temperature Wear Resistance Coatings A New Solution to Save Production Costs in the Deposition of the Wear-Resistant Coating 1 Introduction 2 Definitions and Phenomena 2.1 Thermal Spray 2.2 Tribology 2.3 Lubrication and Lubricant 2.4 Wear and Wear Resistance 2.5 Gas Generation Plasma 2.6 Amorphous Alloy 2.7 Coefficient of Friction 2.8 Enthalpy 2.9 The Adhesion and Cohesion Bond 2.10 Deposition Coating 3 Materials for High-Temperature Coating 3.1 The Improvement of Wear-Resistant Materials 3.2 Relation Between the Wear and Hardness 3.3 Relation Between the Wear and Friction 4 Methodology for Evaluating the Performance of the Deposition 4.1 Porosity—Its Influence on the Quality of Coating 4.2 Measurement of the Wear Resistance 4.3 Corrosion Test 4.4 Adhesive Test 4.5 Thermal Insulation Test 4.6 Hardness Testing 4.7 Measurement of Enthalpy 4.8 Determination of the Velocity of Particles in Plasma Spraying 5 Conclusions References Wear/Erosion Resistant High-Temperature Coatings 1 Introduction 2 Technology Advancement in High-Temperature Erosive Wear Resistance 3 Parameters Influencing Erosive Wear 4 Advance Coating Techniques 4.1 Thermal Spray Techniques 5 Erosive Wear Resistance of Ceramic Coatings 6 Erosive Wear Resistance of Metallic Coatings 7 Erosive Wear Resistance of Composite Coatings 8 Erosive Wear Resistance of Super Alloy Coatings 9 Coatings Failure at High-Temperature Conditions 9.1 High-Temperature Oxidation 9.2 Hot Corrosion 9.3 Solid-State Diffusion 10 Summary and Future Scope References Research on Anti-Oxidation and Wear-Resistance Co–Cr–Fe–Nb–Ni High Entropy Alloys Coatings Prepared by Laser Cladding 1 Introduction 1.1 Protection Requirement for Oxidation/Wear Resistance at High Temperature 1.2 High-Entropy Alloy Properties 1.3 Laser Cladding High-Entropy Alloys Coatings 2 The Microstructure Co–Cr–Fe–Nb–Ni Coating 2.1 Effect of Cr Content on the Microstructure 2.2 Effect of Si Addition on the Microstructure 2.3 Effect of C Addition on the Microstructure 2.4 Effect of CeO2 Addition on the Microstructure 3 The Oxidation Behavior of Co–Cr–Fe–Nb–Ni Coatings 3.1 The Role of Cr on Wet Mixture Gas Oxidation 3.2 The Role of Si on Wet Mixture Gas Oxidation 3.3 The Influence of C and CeO2 on High-Temperature Oxidation 4 The Wear Mechanisms of Co–Cr–Fe–Nb–Ni Coatings 4.1 The Influence of C Addition on Hardness 4.2 The Wear Mechanisms of HEAs Coatings at Elevated Temperature 5 Comparison of HEAs Coatings to Electroplated Hard Cr 5.1 The Oxidation Behavior of Two Coatings 5.2 The Wear Behavior of Two Coatings 6 Conclusion References The Boriding Process for Enhancing the Surface Properties of High-Temperature Metallic Materials 1 The Boriding Process 1.1 The Boriding Techniques 2 The Adhesion Resistance of Boride Coating on Metallic Substrates 3 High-Temperature Wear of Boride Coatings 3.1 High-Temperature Wear Resistance of Borided Steels 3.2 High-Temperature Wear Performance of Borided Ni-Base Superalloys 4 Oxidation and Corrosion Resistance of Boride Coatings in Aggressive Environments 4.1 Oxidation Behavior of Borided Metallic Materials 4.2 Corrosion Resistance of Boride Coatings to Neutral and Acidic Solutions 5 Tribocorrosion of Borided Metallic Materials References Tribological Characterization of Electroless Nickel Coatings at High Temperatures 1 Introduction 2 Deposition of EN Coatings 3 Coating Characteristics 4 High-Temperature Tribological Behaviour of EN Coatings 4.1 Performance of Ni–P Coatings at High Temperatures 4.2 Performance of ENB Coatings at High Temperatures 5 Conclusions and Future Directions References Heat Resistant Coatings Thin Chromium-Based Coatings for Internal Combustion Automobile Engine Valve Protection 1 Introduction 2 Operating Conditions of the Internal Combustion Automobile Engine Valves 3 Methods for Testing the Oxidation Resistance of Materials Used in the Manufacture of Engine Valves 4 Corrosion Behavior of Popular Automobile Engine Valve Steels at High Temperatures 4.1 Oxidation in Air Atmosphere 4.2 Oxidation in Combustion Gasses of Fuels Containing Bio-Additions 4.3 Oxidation in Combustion Gasses of LPG Fuel 5 Thin Chromium-Based Coating Protective Properties Against High Temperature Oxidation of Valve Steels 5.1 Chromium Coatings 5.2 Chromium–Nickel Coatings 6 Summary References Protective Coatings for High-Temperature Thermoelectric Materials 1 Thermoelectric Materials—Introduction 2 Coatings 2.1 Background of Coating Techniques 2.2 Components of Coating Materials and Its Importance 2.3 Different Stages to Coat Materials 2.4 Coatings for High Temperature 2.5 Challenges in High-Temperature (HT) Coatings 2.6 Different Types of Coatings 3 Applications 3.1 Coatings for Gas Turbines 3.2 Coatings for Solar Thermal Power 3.3 Coatings for Space Applications 3.4 Coatings for Marine Applications 4 Existing Materials for Protective Coatings 4.1 Superalloys 4.2 Ceramics 4.3 Intermetallics 4.4 Refractory Materials 5 Explored High-Temperature Protective Coatings for TEM 6 Future Outlook 7 Summary References Electrically Insulating Corrosion-Resistant Tritium Permeation Barrier Coatings for High Temperature Liquid Metal Breeders of Nuclear Fusion Reactors 1 Introduction 2 Experimental Methods and Materials 3 Results and Discussions 3.1 Coating Observations 3.2 Electrical Insulation Performance in High Temperature Molten PbLi Environment 4 Metallographic Investigations 5 Applications and Outlook 5.1 Development of a Two-Phase Detection Probe for High Temperature Liquid Metal Systems 5.2 Development of Electrically Decoupled Liquid Metal Flow Channels 6 Conclusions Appendix A: Estimation of Volumetric Electrical Resistivity and Coating Resistance References Silicone-Based Coatings for High-Temperature Applications 1 Introduction 2 Silicone Materials and Their Unique Properties 3 Types of Silicone Coatings and Its Performance at High Temperature 3.1 Silanes 3.2 Polydimethylsiloxane (PDMS) 3.3 Silicone Polyethers 3.4 Silicone Resins 3.5 Silicone Elastomers 4 High-Temperature Coating Applications of Silicone Materials 4.1 Aerospace and Aviation 4.2 Automotive Industry 4.3 Oil and Gas Industries 5 Factors Affecting the Performance of Silicone Coatings in High-Temperature Environments 6 Performance of Silicone-Based Coatings in High-Temperature Applications 6.1 Effects of Temperature, Stress, and Exposure Time on the Performance of Silicone-Based Coatings 6.2 Comparison of the Performance of Silicone-Based Coatings with Other High-Temperature Coating Materials 7 Future Directions and Conclusions 7.1 Future Research Directions on the Development of Advanced Formulations and Manufacturing Processes 7.2 Conclusion and Recommendations for Future Work in the Field of Silicone-Based Coatings for High-Temperature Applications References Heat Resistant Coatings—An Overview 1 Introduction 2 Requirement for Heat Resistant Coating 3 Classification of Heat Resistant Coating Materials 3.1 Ceramic Heat Resistant Coating Materials 3.2 Metallic Heat Resistant Coating Materials 3.3 Nanostructured Heat Resistant Coating Materials 4 Preparation of Heat Resistant Coating Materials 4.1 Electron Beam—Physical Vapor Deposition Method (EB-PVD) 4.2 Plasma Spray Method 4.3 Chemical Vapor Deposition Method (CVD) 5 Properties of Heat Resistant Coating Materials 5.1 Mechanical Properties 5.2 Thermo Physical Properties 5.3 Failure Behavior 6 Performance of Heat Resistant Coating Materials 6.1 Oxidation 6.2 Failure Mechanisms 6.3 Degradation Mechanisms 7 Newer Materials for Heat Resistant Coating 7.1 Chemically Modified Yttria Stabilized Zirconia (YSZ) 7.2 Pyrochlore Oxides (A2B2O7) 7.3 Lanthanum Cerium Oxide (La2Ce2O7) 7.4 Silicates 7.5 Rare Earth Oxides 7.6 Y3Al5O12 7.7 Lanthanum Aluminates 7.8 LaPO4 7.9 Metal–Glass Composite (MGC) 8 Conclusion References