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Slurry Erosion Performance of Ni-Al2O3 Based Thermal-Sprayed Coatings: Effect of Angle of Impingement

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Abstract

In this paper, slurry erosion performance of high velocity flame-sprayed Ni-Al2O3 based coatings was evaluated. The coatings were deposited on a hydroturbine steel (CA6NM) by varying the content of Al2O3 in Ni. Using jet-type test rig, erosion behavior of coatings and bare steel was evaluated at different impingement angles. Detailed investigation of the surface morphology of the eroded specimens was undertaken using SEM/EDS to identify potential erosion mechanism. A parameter named “erosion mechanism identifier” (ξ) was used to predict the mode of erosion. It was observed that the coating prepared using 40 wt.% of Al2O3 showed a highest resistance to erosion. This coating enhanced the erosion resistance of the steel by 2 to 4 times. Spalling in the form of splats and chunks of material (formed by interlinking of cracks) along with fracture of Al2O3 splats were identified as primary mechanisms responsible for the loss of coating material. The erosion mechanism of coatings and bare steel predicted by ξ was in good agreement with that observed experimentally. Among different parameters,\( \left( {K_{\text{IC}}^{2} H} \right)^{1/3} \), a function of fracture toughness (K IC) and hardness (H) showed excellent correlation with erosion resistance of coatings at both the impingement angles.

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Acknowledgments

Authors thankfully acknowledge the financial assistance provided by Council of Scientific and Industrial Research (CSIR), India, under project title “Development of Slurry Erosion Resistant Coatings for Hydroturbines”, File No. 22(0604)/12/EMR-II.

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Authors and Affiliations

  1. School of Mechanical, Materials and Energy Engineering, Indian Institute of Technology Ropar, Rupnagar, India

    H. S. Grewal, Anupam Agrawal & H. Singh

  2. Department of Materials, Imperial College London, London, SW7 2BP, UK

    B. A. Shollock

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  1. H. S. Grewal
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  2. Anupam Agrawal
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  3. H. Singh
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  4. B. A. Shollock
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Correspondence to H. Singh.

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Grewal, H.S., Agrawal, A., Singh, H. et al. Slurry Erosion Performance of Ni-Al2O3 Based Thermal-Sprayed Coatings: Effect of Angle of Impingement. J Therm Spray Tech 23, 389–401 (2014). https://doi.org/10.1007/s11666-013-0013-x

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  • DOI: https://doi.org/10.1007/s11666-013-0013-x

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