A Novel Plasma Spray NiCr/Al2O3 and Cr2C/ Al2O3 Coating Design for Hot Corrosion Prevention and to Enhance the Efficiency in Boiler Tubes

In the rigorous environment of boiler operations, corrosion harms the longevity and performance of crucial elements such as boiler tubes.To address this issue, the current work looks at the hot corrosion confrontation of Cr2C and Ni-Cr based type of coatings applied through plasma spray in a replicated boiler environment.The coatings, which include NiCr /Al2O3 and Cr2C /Al2O3, are applied to T22 steel substrates and extensively evaluated under circumstances that replicate the corrosive environment encountered during boiler operation.The efficiency of these coatings in preventing corrosion and maintaining the structural strength of T22 steel substrate is systematically evaluated using extensive analytical techniques such as corrosion testing, microscopy, and material characterization.The results show that NiCr and Cr2C based coatings function well, with significant increases in corrosion resistance compared to uncoated substrates.Furthermore, the impact of composition of coating and microstructure on corrosion behaviour is examined, giving important information for the development of new corrosion -resistant materials for boiler applications.Overall, this work contributes to current efforts to improve boiler dependability, longevity, and operating efficiency by utilizing new coating methods.