High temperature corrosion resistant thermal spray coated and HIPed FeNiCrAl for oxycombustion application

CCS (carbon capture and storage) and oxyfuel combustion aim for decreasing CO2 emissions in energy production using fossil fuels. The conditions in power plant boilers using oxygen firing will change from conventional firing. This means that higher material temperatures, more harsh and variable environmental conditions, and new degradation processes that are not yet fully identified will be encountered. The aim of this study was to develop and manufacture FeCrAl alloy by P/M methods and evaluate the developed material in oxyfuel conditions. Thermodynamic calculations were used for material selection. The Fe-Ni-Cr-Al powder was manufactured by gas atomization. The powder was used for thermal spraying of coatings by HVOF (high velocity oxy-fuel) and for hot isostatic pressing of bulk specimens. The high temperature corrosion properties of manufactured FeNiCrAl coating and bulk material were tested in laboratory conditions simulating oxycombustion. The characterization of the materials before and after the testing was performed with optical microscopy, and scanning electron microscopy together with EDX. The manufacturing methods and the results of high temperature corrosion performance are presented