生物质锅炉抗高温腐蚀涂层材料的研究
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摘要
生物质锅炉管道的高温腐蚀问题严重影响锅炉的安全运行和使用寿命,已造成巨大的经济损失,采用电弧喷涂在炉管表面形成防护涂层技术是最为有效的方法之一,研制具有优良耐高温腐蚀性能的电弧喷涂材料及涂层成为一个极具现实意义的课题。
本文研制新型NiCrTi/304粉芯丝材,用超音速电弧喷涂技术在20钢表面制备四种NiCrTiFe涂层。对不同粉芯成分的四种NiCrTiFe涂层进行对比试验研究,应用金相显微镜、扫描电子显微镜(SEM)结合能谱仪(EDS)、X射线衍射仪(XRD)等分析手段研究超音速电弧喷涂NiCrTiFe涂层的显微组织、相结构、显微硬度、结合强度、内聚强度、热震性能、抗高温氧化性能和抗高温腐蚀性能。
试验结果表明:采用超音速电弧喷涂制备的NC1、NC2、NC3、NC4四种涂层,其组织结构主要由白色固溶体相(Fe-Cr-Ni固溶体)、少量的灰色氧化物相(Fe-Cr氧化物、Fe2O3)和黑色的孔隙组成。NC系列涂层均呈层状组织结构,组织致密,没有明显的粗大孔隙和裂纹。NC系列涂层具有较高的硬度、结合强度、内聚强度和良好的热震性能,可以达到锅炉管道的实际使用要求。NC系列涂层在800℃的氧化动力学曲线呈抛物线规律,均表现出优良的抗高温氧化性能,100小时氧化试验证实,其抗高温氧化性能与锅炉管道用钢20钢相比高出12~16倍。NC系列涂层在800℃的腐蚀动力学曲线也呈抛物线规律,具有优良的抗高温腐蚀性能,90小时腐蚀试验证实,NC系列涂层的抗高温腐蚀性能比20G提高4.4~9.4倍。
根据对四种喷涂材料及其涂层组织结构与性能的试验及分析,结果表明:相比于其它三种涂层,NC1涂层具有致密均匀的组织结构、较高的显微硬度、较好的结合强度、内聚强度和热震性能,最好的抗高温氧化和抗高温腐蚀性能,可以推荐作为生物质锅炉管道的防高温腐蚀涂层材料进行现场试用,取得试用结果后再进行推广应用。
The serious high temperature corrosion problem of biomass boiler tubes severely impacts the running of boilers and maybe takes huge economic loss. Using arc spraying to prepare coatings on surface of the boiler tubes is considered as one of the most efficient approaches. So, the research and development of arc spraying materials and coatings which have excellent property of high temperature corrosion resistances has been one most meaningful subject.
According to these problems, a new NiCrTi/304 cored wire has been developed. in this article. Supersonic arc spraying techniques was applied to produce four NC coating on 20G. Microstructures and phase structures of four different component coatings have been analyzed by using modern testing techniques,such as,metalloscope,scanning electron microscopy(SEM),energy dispersive spectrometry(EDS), X-ray diffractometry(XRD), et al. The microhardness, bond strength, cohesive force, thermal shock resistance, high-temperature oxidation resistance and high-temperature corrosion resistance have been studied through a series of experiments.
The results show that: The structure of the four coatings as NC1, NC2, NC3andNC4 prepared by supersonic arc spraying consists of such as white solid solutions phases(Fe-Ni solid solutions), small amounts of gray oxides phases(Fe-Cr composite oxide,Fe2O3) and black fine holes and so on. The microscopic structure of coatings appears typical layered structure characteristics. Series of NC coatings have high dense, have no significant massive holes and cracks. Series of NC coatings have quite high hardness, bond strength, cohesive force and favorable thermal shock resistance, can reach the application requirement of boiler tubes. The oxidizing dynamics curve at 800℃of coatings had parabolic law, show excellent high-temperature oxidation resistance. After 100 hours test, high-temperature oxidation resistance of coatings are 12 to16 times that of 20G. The corrosion dynamics curve at 800℃of coatings had parabolic law, show excellent high-temperature corrosion resistance. After 90 hours test, high-temperature corrosion resistance of coatings are 4.4 to9.4 times that of 20G.
According to the results of tests and analysis on the structure and properties of these four spraying materials and coatings, conclusions show as follow: NC1 coatings have compact and uniform structure, higher microhardness, enough bond strength, cohesive force and favorable thermal shock resistance, best high-temperature oxidation resistance and high temperature corrosion resistance which can be recommended use on the site as anti-corrosion protecting coatings on biomass boiler tubes so as to be greatly popularized after trying on the site.
本文研制新型NiCrTi/304粉芯丝材,用超音速电弧喷涂技术在20钢表面制备四种NiCrTiFe涂层。对不同粉芯成分的四种NiCrTiFe涂层进行对比试验研究,应用金相显微镜、扫描电子显微镜(SEM)结合能谱仪(EDS)、X射线衍射仪(XRD)等分析手段研究超音速电弧喷涂NiCrTiFe涂层的显微组织、相结构、显微硬度、结合强度、内聚强度、热震性能、抗高温氧化性能和抗高温腐蚀性能。
试验结果表明:采用超音速电弧喷涂制备的NC1、NC2、NC3、NC4四种涂层,其组织结构主要由白色固溶体相(Fe-Cr-Ni固溶体)、少量的灰色氧化物相(Fe-Cr氧化物、Fe2O3)和黑色的孔隙组成。NC系列涂层均呈层状组织结构,组织致密,没有明显的粗大孔隙和裂纹。NC系列涂层具有较高的硬度、结合强度、内聚强度和良好的热震性能,可以达到锅炉管道的实际使用要求。NC系列涂层在800℃的氧化动力学曲线呈抛物线规律,均表现出优良的抗高温氧化性能,100小时氧化试验证实,其抗高温氧化性能与锅炉管道用钢20钢相比高出12~16倍。NC系列涂层在800℃的腐蚀动力学曲线也呈抛物线规律,具有优良的抗高温腐蚀性能,90小时腐蚀试验证实,NC系列涂层的抗高温腐蚀性能比20G提高4.4~9.4倍。
根据对四种喷涂材料及其涂层组织结构与性能的试验及分析,结果表明:相比于其它三种涂层,NC1涂层具有致密均匀的组织结构、较高的显微硬度、较好的结合强度、内聚强度和热震性能,最好的抗高温氧化和抗高温腐蚀性能,可以推荐作为生物质锅炉管道的防高温腐蚀涂层材料进行现场试用,取得试用结果后再进行推广应用。
The serious high temperature corrosion problem of biomass boiler tubes severely impacts the running of boilers and maybe takes huge economic loss. Using arc spraying to prepare coatings on surface of the boiler tubes is considered as one of the most efficient approaches. So, the research and development of arc spraying materials and coatings which have excellent property of high temperature corrosion resistances has been one most meaningful subject.
According to these problems, a new NiCrTi/304 cored wire has been developed. in this article. Supersonic arc spraying techniques was applied to produce four NC coating on 20G. Microstructures and phase structures of four different component coatings have been analyzed by using modern testing techniques,such as,metalloscope,scanning electron microscopy(SEM),energy dispersive spectrometry(EDS), X-ray diffractometry(XRD), et al. The microhardness, bond strength, cohesive force, thermal shock resistance, high-temperature oxidation resistance and high-temperature corrosion resistance have been studied through a series of experiments.
The results show that: The structure of the four coatings as NC1, NC2, NC3andNC4 prepared by supersonic arc spraying consists of such as white solid solutions phases(Fe-Ni solid solutions), small amounts of gray oxides phases(Fe-Cr composite oxide,Fe2O3) and black fine holes and so on. The microscopic structure of coatings appears typical layered structure characteristics. Series of NC coatings have high dense, have no significant massive holes and cracks. Series of NC coatings have quite high hardness, bond strength, cohesive force and favorable thermal shock resistance, can reach the application requirement of boiler tubes. The oxidizing dynamics curve at 800℃of coatings had parabolic law, show excellent high-temperature oxidation resistance. After 100 hours test, high-temperature oxidation resistance of coatings are 12 to16 times that of 20G. The corrosion dynamics curve at 800℃of coatings had parabolic law, show excellent high-temperature corrosion resistance. After 90 hours test, high-temperature corrosion resistance of coatings are 4.4 to9.4 times that of 20G.
According to the results of tests and analysis on the structure and properties of these four spraying materials and coatings, conclusions show as follow: NC1 coatings have compact and uniform structure, higher microhardness, enough bond strength, cohesive force and favorable thermal shock resistance, best high-temperature oxidation resistance and high temperature corrosion resistance which can be recommended use on the site as anti-corrosion protecting coatings on biomass boiler tubes so as to be greatly popularized after trying on the site.
引文
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