Performance Analysis of Computer Controlled Thermal Spraying on Hot Corrosion Control of Boiler Tube Steels

The surface degradation due to hot corrosion and erosion in thermal power plants is one of the primary concerns for many researchers. Hot corrosion is considered as a serious problem in coal-based thermal power plants which fulfill approximately 58.3 % requirement of the total electricity demand of India. The practice of using low-grade fuels at high functional temperatures is the overriding reason of accelerated hot corrosion. A case study stated that out of 89 boiler failures 50 boiler failures occur in a year, due to hot corrosion. This leads to reduced economical efficiency of the thermal power plants. This problem cannot be eliminated completely but it can be controlled to some extent. Surface modification is one of the effective methods to enhance the life of boiler components. For Minimise the economical loss and probability of premature failure of the engineering components different researchers investigated and concluded that those different computer-controlled coating processes are helpful to enhance the lifespan of different engineering components. In this study, we will discuss performance analysis of different computer-controlled thermal spraying process. We will review the effects of various types of the thermal spray processes such as plasma spray, HVOF and D-gun, to develop the corrosion resistance surface properties on different substrate materials.