Slurry erosion performance study of HVFS sprayed Ni-20Al2O3 and Ni-15Al2O3-5TiO2 coatings under hydro accelerated conditions

Abstract

Purpose This paper aims to cover all the aspects of development, investigation and analysis phases to evaluate the slurry erosion performance of test coatings. The powders having composition of Ni-20Al2O3 and Ni-15Al2O3-5TiO2 were deposited on CA6NM grade turbine steel by using high velocity flame spray (HVFS) technique. The characterization of the coatings was done with the help of SEM/EDS and XRD techniques. Various properties such as micro-hardness and bonding strength of the coatings were also evaluated. Thereafter, these coatings were subjected to an indigenously developed high speed slurry erosion tester at different levels of rotational speed, erodent particle size and slurry concentration. The effect of these parameters on the erosion behavior of coatings was also evaluated. The slurry erosion tests and SEM of the eroded surfaces revealed remarkable improvement in slurry erosion resistance of Ni-15Al2O3-5TiO2 coating in comparison with Ni-20Al2O3 coating. Design/methodology/approach Two different compositions of HVFS coating were developed onto CA6NM steel. Subsequently, these coatings were evaluated by means of mechanical and microstructural characterization. Further, slurry erosion testing was done to analyze the erosive wear behavior of developed coatings. Findings The coatings were successfully developed by HVFS process. Cross-sectional microscopic analysis of sprayed coatings revealed a continuous and defect-free contact between substrate and coating. Ni-15Al2O3-5TiO2 coating showed higher value of bond strength in comparison with Ni-20Al2O3 coating. Under all the testing conditions, Ni-15Al2O3-5TiO2 coatings showed higher resistance to slurry erosion in comparison with Ni-20Al2O3 coatings. Rotational speed, average particle size of erodent and slurry concentration were found to have proportional effect on specific mass loss of coatings. The mixed behavior (brittle as well as ductile) of the material removal mechanism was observed for the coatings. Originality/value From the literature review, it was found that researchers have documented the various studies on Ni-Al2O3, Ni-TiO2 and Al2O3-TiO2 coatings. No one has ascertained the synergetic effect of Alumina and Titania on the slurry erosion performance of Nickel-based coating. In view of this, the authors have developed Ni-Al2O3 and Ni-Al2O3-TiO2 coatings, and an attempt has been made to compare their mechanical, microstructural and slurry erosion characteristics.