Remarkable Potential of Cold Spray in Overlay Restoration for Power Plants: Key Challenges, Recent Developments, and Future Prospects

Author:

Afandi Nurfanizan12ORCID,Mahalingam Savisha3ORCID,Tan Adrian4ORCID,Manap Abreeza12ORCID,Mohd Yunus Salmi5,Sun Wen6,Zulkipli Asiah1,Chan Xin4ORCID,Chong Adrian4,Om Nur13,Bhowmik Ayan7ORCID

Affiliation:

1. Department of Mechanical Engineering, College of Engineering, Universiti Tenaga Nasional, Jalan IKRAM-UNITEN, Kajang 43000, Selangor, Malaysia

2. Institute of Power Engineering, Universiti Tenaga Nasional, Jalan IKRAM-UNITEN, Kajang 43000, Selangor, Malaysia

3. Institute of Sustainable Energy, Universiti Tenaga Nasional, Jalan IKRAM-UNITEN, Kajang 43000, Selangor, Malaysia

4. Smart Manufacturing and Systems Research Group (SMSRG), University of Southampton Malaysia, Iskandar Puteri 79100, Johor, Malaysia

5. Materials Engineering and Testing Group, TNB Research Sdn Bhd, Kawasan Institusi Penyelidikan, No. 1 Lorong Ayer Itam, Kajang 43000, Selangor, Malaysia

6. National Engineering Laboratory for Modern Materials Surface Engineering Technology, Institute of New Materials, Guangdong Academy of Sciences, Guangzhou 510650, China

7. Department of Materials Science and Engineering, Indian Institute of Technology Delhi, Hauz Khas, New Delhi 110016, India

Abstract

Cold spray has become a prominent deposition technology for coating, repair, and restoration in many industries, such as the aerospace, automotive, and power generation industries. It also has the potential to be used as an alternative overlay restoration for power plant components as it has minimal thermal distortion phase changes, as compared to conventional welding and thermal spray. This article aims to bridge the gap in the scientific literature by presenting a comprehensive review of cold spray in the context of power plant components. Firstly, this review examines the challenges of cold spray and subsequently elucidates effective mitigation strategies. Secondly, the review analyses the recent development of cold spray in the field of coating application. Moving forward, it investigates the integration of cold spray technology in repair applications, focusing on practical implementation and effectiveness. Finally, the review presents the overall impact of cold spray, its current outlook, and discusses future prospects. As such, the review will provide the community with a broad understanding of cold spray applications in the power plant sector.

Funder

Universiti Tenaga Nasional

Publisher

MDPI AG

Subject

Materials Chemistry,Surfaces, Coatings and Films,Surfaces and Interfaces

Reference138 articles.

1. International Energy Agency (2023, August 28). Surging Electricity Demand Is Putting Power Systems under Strain around the World. Available online: https://www.iea.org/news/surging-electricity-demand-is-putting-power-systems-under-strain-around-the-world.

2. Jones, N.I. (2023, August 28). Preventing Power Plant Damages: Erosion, Corrosion, and Foreign Objects. Available online: https://www.ge.com/power/transform/article.transform.articles.2017.aug.preventing-power-plant-damages.

3. Polygon (2023, August 28). How Corrosion Damages Power Plants. Available online: https://www.polygongroup.com/en-US/blog/how-corrosion-damages-power-plants/.

4. Wang, Q.J., and Chung, Y.-W. (2013). Encyclopedia of Tribology, Springer.

5. (2023, September 15). What Is Weld Overlay?. Available online: https://www.hardfacingfty.com/what-is-the-difference-between-cladding-and-weld-overlay/.

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