Microstructure and high-temperature oxidation behaviour of HVOF and plasma sprayed Ni–Cr-based ceramic coatings on SA516 boiler steel
- 1Department of Mechanical Engineering, IK Gujral Punjab Technical University, Kapurthala, Punjab, 144603, India
- 2Department of Mechanical Engineering, IK Gujral Punjab Technical University, Kapurthala, Punjab, 144603, India; Corresponding author.
- 3CGC-College of Engineering, Chandigarh Group of Colleges, Landran, Mohali, Punjab, 140307, India
Abstract
This study investigates the microstructural and high-temperature oxidation behaviour of SA516 boiler steel coated with Ni-20Cr, Ni-20Cr+40TiC, and Ni-20Cr+40TiN using High Velocity Oxygen Fuel (HVOF) and Plasma Spray (PS) techniques. The cyclic air oxidation tests were performed for fifty cycles at 900°C in a simulated laboratory environment, and the resulting microstructural and phase changes were analyzed by means of X-ray Diffraction (XRD), Scanning Electron Microscopy with Energy Dispersive Spectroscopy (SEM/EDS), and X-ray mapping. The uncoated SA516 steel experienced intense spalling and cracking of the oxide layer, developing an unprotected phase (Fe 2 O 3 ). Among all coatings, the HVOF-sprayed Ni-20Cr+40TiC coating diminished maximum weight gain by 95.71% compared to bare SA516 steel, indicating superior oxidation resistance. This enhanced performance of coatings is attributed to formation a dense, protective oxide layer consisting of Cr 2 O 3 , TiO 2 , NiTiO 4 , and NiO, coupled with reduced porosity and enhanced microhardness.
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BibTeX
@article{gill2026microstructure,
title = {{Microstructure and high-temperature oxidation behaviour of HVOF and plasma sprayed Ni–Cr-based ceramic coatings on SA516 boiler steel}},
author = {Ankur Gill and Vikas Chawla and Amit Handa and Santosh Kumar},
journal = {Results in Surfaces and Interfaces},
year = {2026},
month = oct,
doi = {10.1016/j.rsurfi.2026.101009},
url = {https://doi.org/10.1016/j.rsurfi.2026.101009},
note = {CC BY},
}
RIS
TY - JOUR
TI - Microstructure and high-temperature oxidation behaviour of HVOF and plasma sprayed Ni–Cr-based ceramic coatings on SA516 boiler steel
AU - Ankur Gill
AU - Vikas Chawla
AU - Amit Handa
AU - Santosh Kumar
PY - 2026
DA - 2026/10/30
JO - Results in Surfaces and Interfaces
DO - 10.1016/j.rsurfi.2026.101009
UR - https://doi.org/10.1016/j.rsurfi.2026.101009
AB - This study investigates the microstructural and high-temperature oxidation behaviour of SA516 boiler steel coated with Ni-20Cr, Ni-20Cr+40TiC, and Ni-20Cr+40TiN using High Velocity Oxygen Fuel (HVOF) and Plasma Spray (PS) techniques. The cyclic air oxidation tests were performed for fifty cycles at 900°C in a simulated laboratory environment, and the resulting microstructural and phase changes were analyzed by means of X-ray Diffraction (XRD), Scanning Electron Microscopy with Energy Dispersive Spectroscopy (SEM/EDS), and X-ray mapping. The uncoated SA516 steel experienced intense spalling and cracking of the oxide layer, developing an unprotected phase (Fe 2 O 3 ). Among all coatings, the HVOF-sprayed Ni-20Cr+40TiC coating diminished maximum weight gain by 95.71% compared to bare SA516 steel, indicating superior oxidation resistance. This enhanced performance of coatings is attributed to formation a dense, protective oxide layer consisting of Cr 2 O 3 , TiO 2 , NiTiO 4 , and NiO, coupled with reduced porosity and enhanced microhardness.
SN - 2666-8459
ER -