3种热喷涂涂层在模拟气氛/煤灰环境下的热腐蚀及失效行为

doi:10.11902/1005.4537.2020.060

中国腐蚀与防护学报

2021, Vol. 41

Issue (3): 369-375 DOI: 10.11902/1005.4537.2020.060

研究报告

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3种热喷涂涂层在模拟气氛/煤灰环境下的热腐蚀及失效行为

熊义¹, 刘光明¹(

), 占阜元², 毛晓飞³, 罗钦², 洪嘉¹, 倪进飞⁴, 刘永强¹

^1.南昌航空大学材料科学与工程学院南昌 330063
^2.国家能源集团丰城发电有限公司丰城 331100
^3.国电科学技术研究院有限公司武汉 430066
^4.广州特种承压设备检测研究院广州 510663

Hot Corrosion and Failure Behavior of Three Thermal Spraying Coatings in Simulated Atmosphere/Coal Ash Environment

XIONG Yi¹, LIU Guangming¹(

), ZHAN Fuyuan², MAO Xiaofei³, LUO Qin², HONG Jia¹, NI Jinfei⁴, LIU Yongqiang¹

^1.School of Materials Science and Engineering, Nanchang Hangkong University, Nanchang 330063, China
^2.CHN Energy Fengcheng Power Generation Co. , Ltd. , Fengcheng 331100, China
^3.Guodian Science and Technology Research Institute Limited, Wuhan 430066, China
^4.Guangzhou Special Pressure Equipment Inspection and Research Institute, Guangzhou 510663, China

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摘要:

采用超音速火焰喷涂技术在T91钢表面制备了45CT、NiCr/Cr₃C₂和NiCrAlY 3种涂层。在T91钢和3种涂层表面涂覆37.5%Na₂SO₄+37.5%K₂SO₄+15%Fe₂O₃+10%SiO₂的合成煤灰后通入模拟烟气在750 ℃下进行腐蚀，获得腐蚀动力学曲线，腐蚀200 h后观察涂层腐蚀前后厚度变化。采用XRD、SEM、EDS对高温腐蚀产物成分、结构、形貌进行分析。结果表明，T91钢腐蚀非常严重，腐蚀产物大量剥落。3种涂层在腐蚀前期均表现为增重，而在腐蚀后期均存在失重现象。经过200 h腐蚀后，45CT、NiCr/Cr₃C₂和NiCrAlY涂层分别减薄25、112.7和93.1 μm。T91钢腐蚀后表面残留的腐蚀产物主要为Fe₂O₃。45CT涂层表面主要的腐蚀产物相为Cr₂O₃，而NiCr/Cr₃C₂和NiCrAlY的腐蚀产物为Cr₂O₃和NiCr₂O₄。所有样品表层腐蚀产物中不同程度均嵌入了煤灰粒子。腐蚀介质会通过涂层扩散到涂层/基体界面导致基体一侧发生腐蚀。45CT、NiCr/Cr₃C₂涂层样品基体处腐蚀严重导致涂层/基体开裂，而NiCrAlY涂层由于孔隙率较低，以及稀土效应，界面的基体侧腐蚀轻微，未出现裂纹。

关键词 ： 45CT, NiCr/Cr₃C₂, NiCrAlY, 热喷涂涂层, 热腐蚀

Abstract：

Three coatings of 45CT, NiCr/Cr₃C₂ and NiCrAlY were prepared on the surface of T91 steel by high velocity oxygen fuel spray. The hot corrosion behavior of the coated steel was examined in a simulated flue gas at 750 ℃ for the prepared samples enveloped with a layer of synthetic coal ash of 37.5%Na₂SO₄+37.5%K₂SO₄+15%Fe₂O₃+10%SiO₂. The sample was weighed at a certain interval to obtain the corrosion kinetic curve. The thickness changes of the coatings before and after 200 h corrosion were measured. The composition, structure and morphology of high temperature corrosion products were characterized by means of XRD, SEM and EDS. The results show that the bare T91 steel suffered from serious corrosion with corrosion products peeled off in large quantities. Mass gain in the early corrosion stage and then mass loss in the late corrosion stage was observed for the three coatings. After 200 h corrosion, the thinning amount of the three coatings 45CT, NiCr/Cr₃C₂ and NiCrAlY was about 25, 112.7 and 93.1 μm, respectively. The corrosion products remaining on the surface of T91 steel after corrosion were identified as mainly Fe₂O₃. The main corrosion products on the surface of 45CT coating was Cr₂O₃. However, the corrosion products of NiCr/Cr₃C₂ and NiCrAlY were Cr₂O₃ and NiCr₂O₄. Some coal ash particles were embedded in the corrosion products. For three coatings, corrosion media would diffuse through the coating to the coating/substrate interface during the test, which would lead to substrate corrosion. The substrate of beneath coatings of 45CT and NiCr/Cr₃C₂ suffered from serious corrosion, which led to cracks formation at the interface of coating and substrate. However, the substrate of beneath NiCrAlY coating showed slight corrosion, which may be ascribed to the low porosity and reactive element effect of rare earth of the coating.

Key words： 45CT NiCr/Cr₃C₂ NiCrAlY thermal spraying coating hot corrosion

收稿日期: 2020-04-06

ZTFLH:

TG174

基金资助:国家自然科学基金(51961028)

通讯作者: 刘光明 E-mail: gemliu@126.com

Corresponding author: LIU Guangming E-mail: gemliu@126.com

作者简介: 熊义，男，1994年生，硕士生

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引用本文:

熊义, 刘光明, 占阜元, 毛晓飞, 罗钦, 洪嘉, 倪进飞, 刘永强. 3种热喷涂涂层在模拟气氛/煤灰环境下的热腐蚀及失效行为[J]. 中国腐蚀与防护学报, 2021, 41(3): 369-375.
Yi XIONG, Guangming LIU, Fuyuan ZHAN, Xiaofei MAO, Qin LUO, Jia HONG, Jinfei NI, Yongqiang LIU. Hot Corrosion and Failure Behavior of Three Thermal Spraying Coatings in Simulated Atmosphere/Coal Ash Environment. Journal of Chinese Society for Corrosion and protection, 2021, 41(3): 369-375.

链接本文:

https://www.jcscp.org/CN/10.11902/1005.4537.2020.060 或 https://www.jcscp.org/CN/Y2021/V41/I3/369

表1 喷涂用粉末名义成分

图1 样品腐蚀动力学曲线和腐蚀前后涂层厚度变化柱形图

图2 试样在750 ℃腐蚀200 h后宏观表面形貌图

图3 样品在750 ℃含0.3%SO2模拟烟气/煤灰中腐蚀200 h后的XRD谱

图4 T91钢及喷涂45CT、NiCr/Cr3C2、NiCrAlY涂层在750 ℃ 含0.3%SO2气氛/煤灰中腐蚀200 h后的表面形貌

图5 T91钢及喷涂45CT、NiCr/Cr3C2、NiCrAlY涂层在750 ℃ 含0.3%SO2气氛/煤灰中腐蚀200 h后的截面形貌

图6 热喷涂涂层的腐蚀和失效模型

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