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Erosion behavior of plasma and DGun sprayed nichrome coatings on 2205 duplex stainless steel

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Abstract

The problems associated with erosion have emerged during the transportation of oil and gas. Piping industries have tried a variety of methods to comprehend the solid particle erosion. One such method is to perform coating on the substrate for effective erosion prevention. This novel work focuses on nichrome coating on duplex stainless steel (DSS2205) by atmospheric plasma spray method (APS) and detonation gun method (DGun), to minimize the erosion behavior. The velocities (150, 175 and 200 m/s), impact angles (30°, 60°, and 90°), and discharge rates (2.5, 3.75, and 5 g/min) were varied to carry out the experiments. Further, the Taguchi method is used for enhancing the performance, process, and reducing experimental cost and time. This method can optimize process parameters by combining the analysis of variance, response surface methodology, and desirability function analysis. It is evident that the coating has a significant influence on erosion behavior. Scanning electron microscope was used to examine at the degraded regions structure. The erosion resistance of the APS and DGun coatings over the uncoated specimens was increased by 29% and 52%, respectively. DGun coated specimens with a discharge rate of 2.56 g/s, flow velocity of 186.09 m/s, and impact angle of 90° were determined to have the optimum erosion rate. The DGun coating outperformed the APS coating due to its lower porosity, higher hardness, better density, and greater micro hardness.

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Authors and Affiliations

  1. Department of Automobile Engineering, Kalasalingam Academy of Research and Education, Krishnankoil, Tamil Nadu, 626126, India

    Roshan Kuruvila

  2. Department of Mechanical Engineering, PSG Institute of Technology and Applied Research, Coimbatore, Tamil Nadu, 641062, India

    S. Thirumalai Kumaran

  3. Faculty of Mechanical Engineering, Kalasalingam Academy of Research and Education, Krishnankoil, Tamil Nadu, 626126, India

    M. Uthayakumar & M. Adam Khan

  4. Department of Mechanical and Mechatronics Engineering, Dhofar University, Salalah City, Sultanate of Oman

    Farooq Ahmed

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  1. Roshan Kuruvila
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Kuruvila, R., Kumaran, S.T., Uthayakumar, M. et al. Erosion behavior of plasma and DGun sprayed nichrome coatings on 2205 duplex stainless steel. Int J Interact Des Manuf 17, 1515–1529 (2023). https://doi.org/10.1007/s12008-022-01196-2

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