An Innovative Review on Protective Coatings Counting Future Trends of Hot Corrosion Prevention
摘要
Hot corrosion poses a substantial challenge to industrial components operating in high-temperature environments, particularly in critical applications such as fireside boiler tubes. This review provides an in-depth exploration of various coating techniques for preventing hot corrosion, emphasizing their pivotal role in mitigating material degradation, and enhancing the longevity of components. Overlay coatings, exemplified by M-Cr-Al-Y formulations, involve applying corrosion-resistant materials like nickel–chromium (Ni-Cr) alloys onto component surfaces. These coatings act as a robust barrier, effectively resisting corrosive compounds. Advanced overlay techniques preserve the mechanical properties of underlying materials while enduring elevated temperatures. Diffusion coatings containing aluminum, chromium, and silicon, play a crucial role in enhancing oxidation resistance at high temperatures. Noteworthy examples include platinum to aluminide coatings, forming a protective alumina layer that significantly minimizes the impact of hot corrosion. Thermal barrier coatings (TBCs) comprising of metallic bond coat and ceramic top coat (often yttria-stabilized zirconia or YSZ), are applied to super-alloy substrates. Serving the dual purpose of insulation and protection, TBCs are instrumental in preventing high-temperature oxidation and hot corrosion. Their application is crucial in safe-guarding gas turbine components and aircraft engine parts. Environmental Barrier Coatings (EBCs) specifically designed for silicon-based ceramics like silicon carbide (SiC), EBCs form a protective layer that minimizes the penetration of corrosive species. These coatings are indispensable in high-temperature environments, significantly preventing hot corrosion in critical components. The overview delves into both traditional and advanced methods for hot corrosion protection. Overlay Coatings and Thermal Barrier Coatings are among the key techniques.