Low-Cost Alloy Coatings by Pulsed Electrodeposition For Combustors
Purpose of the research: The objective of this program was to demonstrate an economical metallic coating application process that can enhance the resistance of biomass combustor elements to elevated operating temperatures, oxidation, and corrosive attack (by halides and water). The goal of developing the FARADAYIC® ElectroDeposition Process was to demonstrate the potential of applying a range of high value coatings ([Ni/Co]-Cr-[Mo]) on targeted low-cost stainless steels and evaluate their corrosion resistance during a number of accelerated corrosion trials. Description of the research carried out: Faraday successfully completed the Phase II program by meeting the Phase II technical objectives that included: 1) optimizing the alloy deposition process and demonstrating its long-term corrosion resistance under simulated bioreactor operations at Faraday, Oak Ridge National Lab, and Colorado State University; 2) scaling the process to coat prototype (alpha-scale) component from cookstove vendors and estimating its application cost; 3) designing systems to accommodate other cookstove components available in patents and literature; and 4) identifying strategic partners to assist in the technology transition to the market. Research findings or results: The following tasks and results were accomplished in this DOE sponsored program to develop and validate a cost-effective manufacturing process for application of high-quality coatings to low cost materials for improved lifetime and durability during biocombustor operation: Improved electrodeposition tooling to minimize electrical connection marks and improved the coating uniformity Demonstrated 60/40 Ni-Cr and Ni25-Co55-Cr20 coatings can withstand high temperature accelerated corrosion exposure for 1000 h Demonstrated wide range of compositions [Co/Ni] – Cr – [Mo/Fe/W] – [Si/Al] coatings can be electrodeposited Prepared coatings on flat panels with different composition of [Co/Ni]–Cr–[Mo/Fe/W]–[Si/Al] Evaluated bulk alloy materials of NiCr, NiCrAl, NiCrSi and FeCrSi from ORNL for comparing accelerated corrosion performance ORNL conducted a 800°C and 500 h total air + 10% H2O + salt screening test (100 h cycles) using small coupons (20 x 10 x 1 mm) to help shake down furnace and get some data on the castings made based on the target coating composition (60Ni-40Cr and 70Ni-20Cr-10Al wt%), also including a set of FeCrSi alloys, and some FeCrAl, 310, 316L, and 446 Identified an optimum substrate of SS410 Identified an optimum coating with a Cr concentration greater than 70 w/w% with Ni or Co Demonstrated in excess of 1000 h lifetime of optimized coatings on SS410 in accelerated corrosion trials at Faraday Demonstrated in excess of 640 h lifetime of optimized coatings in on SS410 in the accelerated simulated cookstove corrosion trials at Colorado State University Demonstrated in excess of 200 h lifetime of optimized coatings on SS410 in two-hundred 1 hour thermal shock tests undertaken at ORNL Estimated the cost of manufacturing these components and found that at a high-volume target of 1,000,000 units per annum, the estimated cost was ~$2.42 per 0.61 ft2 unit with 0.004” of 10/90 w/w% NiCr coating. Demonstrated that the FARADAYIC® ElectroDeposition Process is economically viable for production of a NiCr coating that has the potential to greatly improve the biocombustor component lifetime. Potential applications of the research: High temperature corrosion resistant coating on a low-cost substrate will facilitate, in part, the viability of advanced biomass combustor systems with resulting environmental and societal benefit in terms of increased energy independence with a reduction in pollution and an increase in US manufacturing jobs. The primary benefits to the Nation as a result of development of a high temperature corrosion resistant coating on low-cost substrates for durable biomass combustor liners include: (i) economic benefit from more facile utilization of an abundant renewable thermal energy resource; and (ii) environmental gains from reduction in non-renewable resource consumption and net greenhouse gas emissions. Economic gains represented by the high temperature corrosion resistant coating on a low-cost substrate for combustor liners will result in lower cost-of-ownership via extended equipment lifetimes. Combined with other innovations such as improved combustor geometries and enhanced catalytic converters, the technology would contribute to a more thorough, more effective, and more economical exploitation of the biomass fuel source. Biomass is currently a minority source of total energy consumption (4.7%) and electrical energy generation (1.9%) in the US; biomass thermal energy represents ~32% of total renewable energy generation in the US. Innovations such as this have the potential to accelerate the “market share” of this important component of the nation’s renewable energy strategy.
- Research Organization:
- Faraday Technology, Inc., Englewood, OH (United States)
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- SC0013870
- OSTI ID:
- 1572199
- Type / Phase:
- SBIR (Phase II)
- Report Number(s):
- DOE-FTE-13870; Faraday-1029
- Country of Publication:
- United States
- Language:
- English
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