• Malik, Nigar Gul
• Paul, Shiladitya
• Martelo, David F.
• Jayakumari, Arunima Bhuvanendran Nair
• Mittal, Garima
• Kale, Namrata

Abstract

<jats:p>In recent years, there has been growing interest in thermal spray techniques using suspension or solution-based coatings. These techniques offer precise control over particle size and microstructure, improving feedstock flowability and allowing for high-quality coatings customization. Spray parameters, such as stand-off distance (SOD) and feedstock flow rate, can alter the performance and characteristics of these coatings. Geothermal power plant heat exchangers often face issues like corrosion, scaling, and fouling. These issues could be mitigated, at least in part, by the use of spray coatings. In this study, TiO2 coatings were applied to a carbon steel substrate using suspension plasma spray (SPS) to enhance the performance of geothermal heat exchanger materials. The impact of SOD (50, 75, and 100mm) and feedstock flow rate (10, 20, and 30 ml/min) on these coatings was examined through various techniques, including SEM, profilometry, XRD, and adhesion testing. The results demonstrated that coatings deposited using 10ml/min feedstock flow rate were well-adhered to the substrate due to efficient melting of coating material but as the SOD and feedstock flow rate increase due to poor thermal and kinetic energy exchange between the torch and feedstock particles, adhesion between coating and substrate decreases. smaller SODs led to more compact coatings, while higher feedstock flow rates increased coating porosity. Smaller SODs and lower flow rates resulted in well-adhered coatings, offering valuable insights for advancing geothermal heat exchanger coatings.</jats:p>

Topics

• Carbon
• corrosion
• scanning electron microscopy
• x-ray diffraction
• steel
• porosity
• spray coating
• profilometry