High-temperature oxidation studies of cold-sprayed Ni-20Cr and Ni-50Cr coatings on SAE 213-T22 boiler steel

The high-temperature oxidation behavior of cold-sprayed Ni-20Cr and Ni-50Cr coatings on SAE 213-T22 boiler steel has been investigated at 900 °C in air under cyclic heating and cooling conditions for 50 cycles. The kinetics of oxidation of coated and bare boiler steel has been established with the help of weight change measurements. It was observed that all the coated and bare steels obeyed parabolic rate law of oxidation. X-ray diffraction, FE-SEM/EDAX and X-ray mapping techniques were used to analyse the oxidation products of the coated and uncoated boiler steel. The uncoated steel suffered corrosion in the form of intense spalling and peeling of its oxide scale, which was perhaps due to the formation of unprotective Fe₂O₃ oxide scale. Both the coatings showed better resistance to the air oxidation as compared to the uncoated steel. The Ni-50Cr coating was found to be more protective than the Ni-20Cr-coated steel. The formation of oxides and spinels of nickel and chromium may be contributing to the development of air oxidation resistance in the coatings.