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<p>Power plant fan blades in boilers suffer severe degradation from combined high-temperature erosion and molten salt corrosion. This study investigates the effect of cobalt content (10, 12, and 17 wt.%) on the performance of HVOF-sprayed WC-Co coatings under simulated service conditions. High-temperature erosion tests (25-400&#xa0;°C) and hot corrosion exposure in Na<sub>2</sub>SO<sub>4</sub>-V<sub>2</sub>O<sub>5</sub> salt at 650&#xa0;°C revealed that WC-12Co exhibits superior erosion-corrosion resistance, outperforming both WC-10Co and WC-17Co. This optimum stems from its dense microstructure (lowest porosity), balanced hardness-toughness, and strong WC-Co interfacial bonding, which collectively suppress salt penetration, crack propagation, and binder oxidation. In contrast, WC-10Co showed high porosity and poor cohesion, accelerating corrosive attack, while WC-17Co suffered from matrix softening and brittle Co-oxide formation, degrading both mechanical and chemical stability. The results demonstrate that 12 wt.% Co represents the ideal composition for harsh boiler environments, offering a microstructure-driven design strategy for durable cermet coatings in energy applications.</p>

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High-Temperature Performance of WC-Co Coatings in Thermal Power Plant Fans: The Role of Cobalt Content on Erosion-Corrosion Resistance

  • 期刊论文

  • 发表日期：

    2026年1月27日

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  • Majid Mirzaee,
  • Erfan Bahrami,
  • Saber Ghannadi,
  • Farhad Hasanabadi,
  • Mehdi Khodaei,
  • Hossein Koohani

摘要

Power plant fan blades in boilers suffer severe degradation from combined high-temperature erosion and molten salt corrosion. This study investigates the effect of cobalt content (10, 12, and 17 wt.%) on the performance of HVOF-sprayed WC-Co coatings under simulated service conditions. High-temperature erosion tests (25-400 °C) and hot corrosion exposure in Na2SO4-V2O5 salt at 650 °C revealed that WC-12Co exhibits superior erosion-corrosion resistance, outperforming both WC-10Co and WC-17Co. This optimum stems from its dense microstructure (lowest porosity), balanced hardness-toughness, and strong WC-Co interfacial bonding, which collectively suppress salt penetration, crack propagation, and binder oxidation. In contrast, WC-10Co showed high porosity and poor cohesion, accelerating corrosive attack, while WC-17Co suffered from matrix softening and brittle Co-oxide formation, degrading both mechanical and chemical stability. The results demonstrate that 12 wt.% Co represents the ideal composition for harsh boiler environments, offering a microstructure-driven design strategy for durable cermet coatings in energy applications.