High temperature erosion of Cr3C2-NiCr thermal spray coatings — The role of phase microstructure

Cr₃C₂-NiCr thermal spray coatings are extensively applied to mitigate erosion at temperatures above 450-550 °C. The aim of this work was to extend the current comparison based knowledge towards a mechanistic interpretation of the high temperature erosion of Cr₃C₂ based thermal spray coatings. Coatings that span the range of industrial quality were assessed. They were eroded under high temperature (700 °C and 800 °C), aggressive (impact velocity 225-235 m/s) conditions designed to simulate the high velocity erodent impacts within a turbine environment. The influence on the erosion response of high temperature induced changes in the coating microstructure and composition with extended in-service exposure was assessed by heat treating selected samples to generate a steady state microstructure prior to testing. In spite of the marked variation in coating microstructure the erosion rates were comparable across the range of coatings tested. The significance of this conclusion is discussed in terms of the erosion mechanism.