Solid Particle Erosion of HVOF Sprayed (35WC-Co/NiCrBSi Coating at Higher Temperature


Raghavendra Naik K
Kumar R K
Saravanan V
Shekhar Kumar M


High temperature erosion is generally encountered in boiler components in thermal power plants, especially in superheater, reheater, and economisers parts, where in fly ash particles attack the boiler components and cause high temperature erosion phenomena. It is known as fly ash erosion. The erosion behavior at elevated temperature is much different from that of room temperature erosion as there would be a higher erosion loss encountered at higher temperature due to higher plastic deformation as well as weak bonding between grains/particles. It is therefore imperative to study in depth the erosion wear assessment both at room temperature as well as at elevated temperature in the laboratory. This paper investigates thermal sprayed coatings produced by the high velocity oxygen fuel (HVOF) to improve the material performance under such conditions. 35 WC-NiCrBSi HVOF sprayed coatings were tested under high temperature (up to 700℃) erosion by means of an apparatus that simulated real conditions. The results showed that under these tests conditions the 35WC-NiCrBSi coating worn about 1.4 times less than bare SS-310 steel at room temperature and 300℃ Temperature, while at 700℃ C 35WC-NiCrBSi worns about 2 times higher than bare SS-310 steel at 90℃ impact angle. This shows 35WC-NiCrBSi erosion sensitivity at higher temperature.


How to Cite
K, R. N., R K, K., V, S., & M, S. K. (2016). Solid Particle Erosion of HVOF Sprayed (35WC-Co/NiCrBSi Coating at Higher Temperature. Power Research - A Journal of CPRI, 12(2), 351–362. Retrieved from


  1. S C Stultz, J B Kitto (Eds), Steam: Its Generation and use, Babcock and Wilcox, Barberton, OH, 1992.
  2. M A Uusitalo, P M J Vuoristo, T A Mantyla, High temperature corrosion of coatings and boiler steels in oxidizing chlorinecontaining atmosphere, Mater. Sci. Eng. A: Struct. 346, 168-177, 2003.
  3. M Hutchings I The erosion of ductile metals by solid partiles. Phd. Disseration , university of Cambridge, pp. 45-52, 1974.
  4. Finnie I Levi AV, Mcfadden DH, “The fundamental mechanism of the erosive wear of ductile metals by solid particles”. ASTM STP 664 Erosion: prevention and useful applications. 1979
  5. J Vicenzi, D L Villanova, HVOF-coatings against high temperature erosion (300° C) by coal fly ash in thermoelectric power plant. Wear 236-242, 2006.
  6. M Suckling, Allen C, Critical variables in high temperature erosive wear. Wear 2034:528-36, 1997.
  7. H Wang, W Xia, Y Jin, A study on abrasive resistance of Ni-based coatingswith a WC hard phase, Wear 195, 47-52, 1996.
  8. P Kulu, T Pihl, Selection criteria for wear resistance powder coatings under extreme erosive wear conditions, J.Therm. Spray Technol. 11 517-522, 2002.
  9. A W Ruff, L K Ives, Measurement of solid particle velocity in erosive wear, Wear 35m 195-199, 1975.
  10. J C Miranda, A Ramalho, Abrasion resistance of thermal sprayed composite coatings with a nickel alloy matrix and a WC hard phase. Effect of deposition technique and re-melting, Tribol. Lett. 11 37-48, 2001.
  11. J Vicenzi, D L Villanova, M D Lima, A S Takimi, C M Marques, C P Bergamann, HVOF-coatings against high temperature erosion (300 deg C) by coal fly ash in thermoelectric power plant, Mater. Des.27, 236-242, 2006.
  12. J R Nicholls, Designing oxidation-resistant coatings, JOM 52, 28-35, 2000.
  13. B S Sidhu, “Studies on the role of coatings in improving resistance to hot corrosion and degradation, Ph.D. Thesis, Met, & Mat. Engg. Dept”., Indian Institute of Technology Roorkee, Roorkee, 2003.
  14. J K N Murthy, D S Rao, B Venkataraman, Effect of grinding on the erosinbehavior of a WC-Co-Cr coating deposited by HVOF and detonation gun sprya processes, Wear 249, 592-600, 2001.
  15. A Levy, GHickey, Erosion of corrosion – resistant surface treatments on alloy steels, Wear 108, 61-79, 1986.
  16. I M Hutchings, Tribology: Friction and Wear of Engineering Materials, Edward Aenold Publication, 1992.
  17. T Sundararajan, M Roy, Solid particle erosion behavior of metallic materials at room and elevated temperatures, Tribol. Int. 30 339-359, 1997.
  18. I Hussainova, J Kubarsepp, I Shcheglov, Investigation of impact of solid particles against hard metal and cermet targets, Tribol. Int. 32, 337-344, 1999.
  19. Z Feng, A Ball, The erosion of four materials using seven erodents-towards an understanding, Wear 233-235, 674-684, 1999.
  20. P Kulu, I Hussainova, R Veinthal, Solid particle erosion of thermal sprayed coatings, Wear 258 488-496, 2005.