Assessment of the microstructure, adhesion and elevated temperature erosion resistance of plasma-sprayed NiCrAlY/cr3C2/h-bn composite coating

This study uses an air jet erosion tester to investigate the erosion behavior of NiCrAlY/Cr 3 C 2 /h-BN composite coatings that are plasma-sprayed at three different temperatures and 40 m/s on T22 boiler steel alloy. 30 and 90° are the impingement angles. To identify the erosion mechanism, SEM and X-ray diffraction techniques are used to analyze the surface morphology and phase generated on the eroded surface. Findings of erosion test indicate that the erosion resistance was notably enhanced by addition of Cr 3 C 2 and h-BN because of its lubricating characteristics and capacity to reduce frictional forces during erosion. The combined influence of Cr 3 C 2 and h-BN enhanced the coating hardness and erosion wear resistance, thereby improving its overall resistance to erosion. The weight loss method was employed to calculate the erosion rate, and the NiCrAlY/Cr 3 C 2 /h-BN coating showed up to 30.55% and 34.48% lower erosion rate as compared to uncoated T22 substrate at 600 °C for 30° and 90° impact angles, respectively. This characteristic is affected by the hard reinforcement Cr 3 C 2 's high-temperature stability, the h-BN's self-lubricating ability, the formation of a protective oxide layer that forms at 600 °C, and the eroded coating's ductile behavior of material removal. The study also reveals that the NiCrAlY/Cr 3 C 2 /h-BN coating system on T22 boiler steel alloy has excellent erosion resistance, making it suitable for use in high-temperature and erosive environments in boiler systems and similar industries. • The NiCrAlY/Cr 3 C 2 /h-BN composite coatings were applied to T22 boiler steel. • Erosion behavior was examined at impingement angles of 30° and 90°, and temperatures of 200 °C, 400 °C, and 600 °C. • The interactions between Cr 3 C 2 , h-BN, and the NiCrAlY matrix have improved the coating's performance. • At 600 °C, oxidation led to the formation of a protective oxide (B 6 O 12 ) layer. • At lower impact angles, the degraded surface of the coating shows patterns of ductile fracture.