High Performance Corrosion Protection for Commercial ......Cross-section SEM and Al compositional...
Transcript of High Performance Corrosion Protection for Commercial ......Cross-section SEM and Al compositional...
High Performance Corrosion Protection
for Commercial Stainless Steels
Matthew M. Seabaugh, Ph.D
Director
June 2, 2015
Presented to:
Overview of Presentation
• Nexceris Introduction
• Potential of Coating Technology
• Overlay Coatings
• Diffusion Coatings
• Emerging Technologies
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COMPANY OVERVIEW
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Corrosion Protection
Near TermProducts
Assess Technology Fit
to Existing Markets
Catalysts
Exhaust Cleanup
Natural Gas Compression
Natural Gas Appliances
Natural Gas Appliances
Refining
Cutting Edge Materials Research
Power Generation
What We Do
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How We Work with Customers
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Natural Gas Appliances
Refining
Catalysts
Corrosion ProtectionWe Provide Unique and Proprietary:
• Coating Capability
• Coating Technology & Know-How
• Catalyst Designs
• Catalyst Formulation & Mfg.
We Are Seeking:
• Partners to Develop New Products
• Partners to Reach Target Markets
• Collaborative Solution Development
for Specific Markets or Customers
Power Generation
NOx Abatement
VOC Abatement
200 μm
Need for Coating Technologies
Coatings Allow Better Materials Design:
• Alloy Selection to Meet Application-Critical Criteria– Mechanical Strength
– Electrical Conductivity
– Thermal Conductivity
– Cost
• Surfaces are Tailored to Create Additional Value:– Corrosion Resistance
– Catalytic Function
– Electrical Function
– Appearance
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Coating Technologies
We Divide High Temp Coatings into Two Categories:
• Overlay Coatings– Metal or Ceramic Coating on Top of Substrate
• Examples: Catalytic Reactors, Electrical Components
– Plasma Spray
– Physical or Chemical Vapor Phase Growth
– Spray and Heat Treat
• Diffusion Coatings– Metal or Ceramic Coating Evolves From Support Alloy
• Examples Aluminides, Carbides, Nitride Coatings
– Vapor Phase/Vacuum Treatments
– Plating and Heat Treat in Controlled Atmosphere
– Atmospheric Spray and Heat Treat
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TECHNOLOGY OVERVIEW
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Overlay Protective Coatings
AL 441-HP substrate
LSM electrode
MCO coating
Chromia scale
AL 441-HP substrate
LSM electrode
MCO coating
Chromia scale
800 hrs 800 °C > 7000 hrs 800 °C/900 °CAfter Deposition
Process Characteristics
• Designed for ferritic stainless steel
• Reduces Cr volatility
• Electrical conductivity can be tailored
• Coatings for oxidizing and reducing
atmospheres
Overlay Coatings on
Complex Metal Surfaces
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200 μm
Overlap and Integration with
Heterogeneous Catalysis
• High Temperature Chemical Reactors
• VOC Oxidation for Stationary Industrial
Systems and H2 abatement systems for
advanced Batteries
• Fuel Reforming and SMR Reactors
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How Are Overlay Coatings Applied?
Non-Protective Coatings
– Dip Coating
– Wash Coating
Protective Coats
– Spray Deposition
– Screen Printing
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Dual MCO/Aluminide Coated Metallic Interconnect Coated Balance of Plant Components
Aluminide seal area coating
MCO active area coating
5 ft. long stainless steel SS316 pipes
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Overlay Protective Coatings
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Diffusion Coating Value Proposition
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Other Features of Aluminide Technology:• Increased Thermal Conductivity• Enhanced Emissivity• Improved Wear Resistance• Simple, Low Cost Application
Oxidation Resistance Coking Resistance
Lower Cost Austenitic Alloys in• Heat Transfer• Corrosion Resistance• Carburization Resistance• Sulfidation Resistance
Diffusion Protective Coatings
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1 inch outer diameter
Uncoated
Coated
• Ferritic (441, 446, Crofer 22APU)• Austenitic (316, 347H)• Inconel (600, 601, 617)• Nickel Alloy 200• Copper Alloys
Phase Diagram of Alloys
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Compositions Evaluated to Date
Diffusion Coating on Stainless Steels
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Cross-section SEM and Al compositional EDS map for Nexceris aluminide coating on Grade 304 stainless steel
B. A. Pint et al., Evaluation of Iron-Aluminide CVD Coatings for High Temperature Corrosion Protection, Materials at High Temperature 18(3) (2001) 1.
Cross-section SEM of aluminide coating produced by CVD on Grade 304
Diffusion Coatings on Superalloys
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Cr
Cross-section SEM for Nexceris aluminide coating on Inconel 617
H. Arabi et al., Formation Mechanism of Silicon Modified Aluminide Coating on a Ni-Base Superalloy, Int. J. Eng. Sci., 19(5-1) (2008) 39.
Cross-section SEM of Si modified aluminide coating produced by pack cementation on IN-738 LC
Oxidation of Common Alloys
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Aluminide coating successfully prevents spallation alloy scale during oxidation
Stainless Steel 316 Stainless Steel 430 Stainless Steel 304
Co
ated
Un
coat
ed
t = 0 t= 50 h
Coated Uncoated
t= 500 h
Substrate: Alloy 304, 316 and 430; Aluminide coating: 20 m fired
Test Conditions: 900 °C, Humidified Air, Isothermal oxidation testing
Comparative Performance of
Coated 430 vs Various Austenitic Steels
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430 Alloy Achieving Corrosion Performance of 4X more expensive 310 Alloy
Propane Torch Stress Tests
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Pass 1 Pass 7-10
Cr Fe
Al Cr Fe
O
t = 0
t = 500 h
Modifying Oxidation Behavior
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•SS316 with Aluminide coating•500 hours in humidified air at 900 °C
Ni O Mo
Al Cr Fe
Ni O Mo
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NexTech’s coating process successfully reproduces the diffusion based surface microstructure produced by more conventional aluminization processes
Vapor Phase Aluminization (VPA) Coating Microstructure on SS316
Al
NexTech’s Aluminide Coating Microstructure on SS316
Al
Cr
Cr
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Performance Comparison
to Vapor Phase Coatings
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Performance Comparison
to Vapor Phase Coatings
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0.0
0.5
1.0
1.5
0 100 200 300 400 500 600 700 800 900 1000
Wei
ght
Ch
ange
/(m
g/c
m2)
Oxidation time /h
Oxidation resistance of coated 316 SS : effect of firing temperature
Al_850C_Average
Al_1000C_Average
Uncoated
VPA
Temperature: 900 °CAtmosphere: Humidified air
Addressing Biomass Derived Contaminants
50h Exposure KCl containing air, 650 °C
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How Does it Work?
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FormHeat Treat
Coat
Coating Application Methods
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c
AerosolDeposition
Also:• Dip Coating• Curtain Coating• Brush Painting• Transfer Printing
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Post Coating Rolling Operation
(304 Stainless Steel)
SEM analysis (Rolled 304 Stainless Steel)
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Rolling operation does not damage the aluminide coating
Rolled component: outside Rolled component: inside Flat component (no forming)
EMERGING APPLICATIONS
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StratalystTM ProductThermal Management and Catalyst Support
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Extending the Design Space
Single Dip Coating in Aluminum & Air Firing
Increased Corrosion ResistanceIncreased Surface Area
Passivation to Chemical Interactions
• Creates New Catalyst Support Product Platform
• Creates Immediate Opportunities in Burner Markets
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The product: Strata-Lyst Nickel Aluminide Catalyst Supports
Porous a-Al2O3 Topcoat
• Open, Interconnected Porosity for Infiltration
• Catalysts Infiltrated to Allow Lower Temp Combustion
Aluminide diffusion coating
• Oxidation resistance
• Enhanced IR Emssivity
• Good Thermal Conductivity
Nickel Skeleton
• Deformability
• Mechanical Robustness
• Lower Cost than Alloys (Mfg. Scale—NiMH Batteries)
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Applications in Burners for
Corrosion Resistant Foams
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Conclusions
• Coatings can protect low-cost alloys in high temperature
environments.
• Overlay coatings approaches offer broad chemical
compositions and tailorable electrical and catalytic properties.
• Diffusion coatings offer excellent thermal stability, corrosion
resistance and damage tolerance.
• Coatings can be applied by low-tech, easily scaled and
adopted technologies with wide process tolerances.
• Technologies in development to create unique coated
composites from a range of iron and nickel alloys.
• We are exploring other alloys for heat exchange applications.
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For Further Information
Matthew M. Seabaugh, Ph.D.
Director
Nexceris
404 Enterprise Drive
Lewis Center, OH 43035
Phone: (614) 842-6606 extension 107
Email: [email protected]
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