Air plasma sprayed metallic coatings for sour environments

Abstract

AbstractAmong protective coatings for components used in petrochemical applications, plasma sprayed alloys containing chromium, nickel, and molybdenum have potential to provide functional surfaces with good resistance to corrosion and wear. They could offer a cost effective solution by limiting the use of expensive bulk materials such as Inconel or Hastelloy superalloys or highly alloyed chromium stainless steels, since a low cost base material could be selected to give the required mechanical strength combined with suitable corrosion resistance from its modified surface. To limit fabrication costs of coating deposition, air plasma spraying techniques can be proposed, but proper optimisation of the plasma processing parameters is required to increase coating performance. In this paper, coatings based on Ni–Cr–B–Si and Mo alloys have been deposited following a design of experiment methodology. Results of characterisation tests for preliminary spraying trials (metallographic, tribological, and corrosion tes...