45CT, Thermal spray wireChemical Content, %
|0.02||0.0015||0.0015||0.3||0.2||42.5|| 0.15||Bal.||0.2||0.47||0.55| Material Review:45CT wire is a Nickel/Chrome/Titanium wire developed specifically for boiler applications. This second generation material is extremely resistant to corrosive vanadium and sulfur gases in boiler atmospheres. The material is prealloyed with titanium to produce superior bond strengths and is suitable for a one-coat system. The unusual self-bonding ability of the alloy is attributed to the exceptionally high temperatures of the metal particles which on impact with the base metal diffuse to form a partial metallurgical bond. Metallurgical tests show negligible chrome loss during spraying. Coating porosities less than one percent are produced with negligible through porosity, thus maximizing the corrosion barrier characteristics of the material.Application Review:This material has proven very effective in providing long term protection to boiler tubes against high temperature sulfidation. The wrought material is highly resistant to sulfur/vanadium atmospheres up to 1800°F. Wrought material of this type has shown a 2 mil per year corrosion rate over a nine year period when used in the super heater section of boilers. Coatings of 45CT wire applied to boiler tubes have shown virtually no loss of thickness or spalling after 24 months of service (as of this writing). Tests have shown the high chromium content, in conjunction with nickel, greatly improves the heat corrosion resistance of the alloy. Specifically, a chromium content of 40% or more is sufficient to form enough chromium oxide to prevent the breakdown of nickel into nickel sulfide which is not a protective layer. Sixty-four day accelerated corrosion tests of this material are highlighted in Figure 1. These tests were all run in the same test boat at the same time to assure identical environments. Specifically the specimens were surrounded with a synthetic smelt consisting of sodium chloride, sodium sulfate and sodium carbonateCoatings made with 45CT wire on the other hand showed virtually no weight loss over the entire 64-day test. This superior corrosion resistance has been proven out in extensive on-line boiler tests.
|Coating Hardness||Min 40HRC|
|Bonding Strength||Min 48 N/mm2|
|Diameter||1.6mm(14 ga), 2.0mm|
|Package Size||10 kg, 15 kg, or up to client's demand|
It is currently the arc spraying nickel-based alloy wire in one of the highest Cr content, resistance to high temperature oxidation corrosion best. After spraying the coating surface will form a dense protective Cr2O3 film, has a very good resistance to high temperature oxidation and SO2, H2S corrosion and heat-resistant corrosion (Na2SO4/K2SO4) performance. In addition, the thermal expansion coefficient of the coating material and the ordinary low carbon and low alloy similar coefficient of thermal expansion, can be avoided during thermal cycling due to flaking of the coating caused by thermal stress. The coating material used in power plant boiler water wall tubes, superheater tubes, turbine blades, reheater tubes and economizer tube temperature corrosion and erosion protection, and paper mill black liquor boilers and waste incinerators, and other working conditions , require a higher level of protection against a similar occasion. The data provided in this document is protected under applicable laws, including but not limited to copyright law and international agreements.