Advanced Materials and Thermal Spray Techniques for Improving Wear and Corrosion Resistance in Boiler Systems

DOI

10.2991/978-94-6239-750-7_35How to use a DOI?

Keywords

Thermal high temperature corrosion; Conventional and Advance coating; Thermal Spray coatings; Nanocomposite

Abstract

Heat transfer deterioration has been the most important issue faced in a thermal power plant because it affects the thermal efficiency, reliability and maintenance cost of the plant. High-temperature corrosion occurs in water walls, superheaters and reheaters. It is caused by high metal temperature, uniform accumulation of ash and corrosive flue gases containing H2S, SO2 and chlorine-containing compounds. The result is a complex of oxidation, sulfidation and chlorination reactions. The use of molten salts and thermal cycling contribute to microstructural damage, spallation of scale, thinned material and ultimately reduced component life. This paper discusses the use of thermal spray coating as a potential long-term solution to the high temperature corrosion problem. Emphasis is placed on nanostructured and composite coating systems like Ni-based alloys, rare-earth-doped oxides, and ceramic-based composites. Such coatings are designed in such a way that they develop thick and well bonded layers which serve as shields against corrosive and erosive assault. Such technologies as HVOF, HVAF, APS, and cold spray are evaluated with a high level of critique regarding the capacity to achieve a coating with low porosity, good interfacial bonding, and high mechanical integrity. Nanoparticles and rare-earth essentials are additional to reduce the permanency of the oxide scales and suppress cracks dissemination. The results include an importance on how a close consideration of coating composition and spray parameters can enhance the durability and working conditions of components of boilers that are subject to temperatures that are extremely high in temperature.

Copyright

© 2026 The Author(s)

Open Access

Open Access This chapter is licensed under the terms of the Creative Commons Attribution-NonCommercial 4.0 International License (http://creativecommons.org/licenses/by-nc/4.0/), which permits any noncommercial use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license and indicate if changes were made.

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TY  - CONF
AU  - Jagmeet Singh
AU  - Charanjit Singh
AU  - Davinder Singh
AU  - Khushdeep Goyal
PY  - 2026
DA  - 2026/08/31
TI  - Advanced Materials and Thermal Spray Techniques for Improving Wear and Corrosion Resistance in Boiler Systems
BT  - Proceedings of the International Conference on Advanced Design, Manufacturing, and Sustainable Energy Systems (ICADMSES 2026)
PB  - Atlantis Press
SP  - 496
EP  - 511
SN  - 2589-4943
UR  - https://doi.org/10.2991/978-94-6239-750-7_35
DO  - 10.2991/978-94-6239-750-7_35
ID  - Singh2026
ER  -