Professional Documents
Culture Documents
Assessment of Nanocoatings
for USC Boilers
Presented by:
D. Gandy (EPRI), Davgandy@epri.com
S. Cheruvu (SWRI), Scheruvu@swri.org
R. Wei (SWRI), Rwei@swri.org
J. Shingledecker (EPRI), Jshingledecker@epri.com
DOE Sponsored Program: DE-FC26-07NT43096
Patricia Rawls, DOE Project Mgr.
Outline
Project Objectives
Background
Modeling of Advanced MCrAl Nanocoatings
Processing Advanced Nanocoatings
Quality Issues
Al Consumption
Fireside Corrosion Testing
Conclusions
Background
Typical boiler wastage rates:
Subcritical 20 mils
(0.5mm)/year
Supercritical 40-100 mils (1.02.5mm)/year
Ni-10% Cr
Conventional
Ni-11% Cr
Nanostructure
Task 1: Computational
Modeling of MCrAl Systems
--completed
Objective: Select potential MCrAl
nanostructured coating compositions
using computational modeling
1600
Fe-Cr-Ni-Al
1400
Temperature, K
Model Recommendation
Coating composition: Fe-30/40Ni-25Cr-10Al
A patent disclosure was filed on the
composition
1200
1000
800
600
No phase
With phase
400
Continuous Al2O3
Application Conditions
200
0
10
12
14
Al Content, Mass %
16
Task 2: Establishment of
Baseline Coating Data
--completed
Objective: Evaluate conventional
coatings and available vendor
nanocoatings to assess properties
0% Al
10% Al
After 990 cycles @750C
1). The protective oxide layer
4% Al
0% Al coating Cr2O3
AC Filament
Power
Supply
Discharge
Power
Supply, Vd,
+ Id
Bias Power
Supply, Vb
Filame
nt
Task 3: Processing of
Advanced NanoCoatings
Filame
nt
--in progress
Samples
Magnetro
n Power
Supply,
P1
Ar, N2,
TMS
Target 1
Magnetron 1
Magnetro
n Power
Supply,
P2
Target 2
Magnetron 2
To Pump
11
12
Discharge
Power
Supply,
Vd,
+
Id
Bias Power
Supply, Vb
Filame
nt
Filame
nt
Samples
Magnetro
n Power
Supply,
P1
Ar, N2,
TMS
AC Filament
Power
Supply
13
Target 1
Magnetron 1
Target 2
Magnetron 2
To Pump
Magnetro
n Power
Supply,
P2
DE-2
DE-1
2000X
DE-3
DE-7
Dense Structure
Columnar Grains
2010 Electric Power Research Institute, Inc. All rights reserved.
14
DE-1
15
Ni-20Cr-10Al
H160-10Al
3500X
3 Nanocoatings
Applied using
Optimized Parameters
2500X
H120-10Al
16
3000X
17
Kernels or Cauliflowers
Crack
19
H160-10Al
H160-10Al
H160-10Al
H160-10Al
Surface Morphology
304-10Al
AlN
AlN
AlN
TiN
Cross Section
2010 Electric Power Research Institute, Inc. All rights reserved.
20
H120+10Al on AlN
H160+10Al on AlN
H188+10Al on AlN
21
Electron
Source
Generated
Plasma
Magnetron
Generated
Plasma
Rotary Table/
Sample holders
Magnetrons
Worktable
22
23
Al
TiN
Kernels or Cauliflowers
Crack
24
25
Shallow defects
No Cracks
Still a few cauliflower defects
26
27
No FeAl
750C
28
Comparison Oxidation Resistance of Nanocoating Ni20Cr-10Al and Plasma-Sprayed NiCoCrAlY & PWA 286
0.000
Ni-20Cr-10Al
0.002
-0.002
-0.004
-0.006
NiCoCrAlY
Plasma Sprayed
-0.008
-0.010
0
1000
2000
3000
0.002
0.000
Ni-20Cr-10Al
-0.002
-0.004
-0.006
PWA 286
Plasma Sprayed
-0.008
-0.010
0
1000
2000
3000
29
Continuous Al2O3
Al rich precipitate
Note: absence of TiN layer
Mixed oxide
NiCoCrAlY
Ni-20Cr-10Al
Al2O3
PWA 286
30
20 m
150kg. Rc Indentation
Al rich interface precipitate
Nanocoating exhibited better
oxidation Resistance than MCrAlY
and PWA 286 at 1010C
Oxidation is not a concern for these
coatings at USC boiler operating
temperatures
No precipitate cracking
2010 Electric Power Research Institute, Inc. All rights reserved.
Vacuum
Feedthrough
Motor-driven
Shaft
Magnetron
Generated
Plasma
Magnetron
Samples
Rotary
Worktable
Ti Target
Filament
Filament
Generated
Plasma
To Pump
32
Waterwall Testing
850F (454C), 975F (524C), and 1100F (593C)
40 percent FeS and 0.2 percent chlorides (same as
USC program)
Superheater/Reheater Testing
1100F (593C), 1300F (704C), and 1500F (816C).
5 percent alkali sulfates (same as USC program)
simulate Eastern bituminous coal compositions.
Perform 1000hr tests (at 100hr intervals).
2010 Electric Power Research Institute, Inc. All rights reserved.
34
Waterwall Conditions
--Results
Commercial Nanocoatings
Relatively porous; provided little protection
Significant penetration of oxide & sulfide
species
Interconnected network of cracks allowed
for penetration
DOE Nanocoatings
Cracking/spallation generally noted
Generally resisted bulk coating corrosion
(some level of protection)
Scattered penetration of oxide and sulfide
species noted @ columnar grain
boundaries and defect sites
Waterwall 1000hr, 975F
35
SH/RH Conditions
--Results
Commercial Nanocoatings
Displayed very poor resistance to
corrosion
No evidence of coating apparent
following exposure
DOE Nanocoatings
Complete consumption of the coating
and subsequent wastage
Degradation generally increased
with test temperature
Some nanocoatings were unstable at
high temperatures
Interdiffusion between coating and
substrate
2010 Electric Power Research Institute, Inc. All rights reserved.
36
37
38
39
extras
40
Al2O3
Al2O3
Al content in the
coating
1.6 wt.%
4%Al
7%Al
41