Journal articles: 'Gas-turbines – Corrosion'

1

Meadowcroft, J. M., and J. Stringer. "Corrosion in coal-fired gas turbines." Materials Science and Technology 3, no. 7 (July 1987): 562–70. http://dx.doi.org/10.1080/02670836.1987.11782268.

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Nicholls, J. R., N. J. Simms, and A. Encinas-Oropesa. "Modelling hot corrosion in industrial gas turbines." Materials at High Temperatures 24, no. 3 (September 2007): 149–62. http://dx.doi.org/10.3184/096034007x263587.

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3

McCreath, C. G. "Hot corrosion site environment in gas turbines." Materials Science and Technology 3, no. 7 (July 1987): 494–500. http://dx.doi.org/10.1080/02670836.1987.11782260.

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4

Condé, J. F. G., G. C. Booth, and A. F. Taylor. "Protection against hot corrosion in marine gas turbines." Materials Science and Technology 2, no. 3 (March 1986): 314–17. http://dx.doi.org/10.1179/mst.1986.2.3.314.

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5

Kanao, H., and T. Doi. "Application of corrosion resistant coatings to gas turbines." Welding International 1, no. 10 (January 1987): 976–82. http://dx.doi.org/10.1080/09507118709449048.

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6

Bavarian, Behzad, Jia Zhang, and Lisa Reiner. "Corrosion Inhibition of Stress Corrosion Cracking and Localized Corrosion of Turbo-Expander and Steam/Gas Turbines Materials." Key Engineering Materials 488-489 (September 2011): 61–64. http://dx.doi.org/10.4028/www.scientific.net/kem.488-489.61.

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Stress corrosion cracking of 7050 aluminum alloys and ASTM A470 steel in the turbo expander and steam/gas turbine industry can cause expensive catastrophic failures, especially for turbo machinery systems performing in hostile, corrosive environments. Commercially available inhibitors were investigated for their effectiveness in reducing and controlling the corrosion susceptibility. Inhibitor effectiveness was confirmed with electrochemical corrosion techniques in different solutions. Polarization resistance increased with concentration of corrosion inhibitor due to film formation and displacement of water molecules. Cyclic polarization behavior for samples in the 1.0% and 5.0% inhibitors showed a shift in the passive film breakdown potential. The substantial increase in the passive range has positive consequences for neutralizing pitting and crevice corrosion cell chemistry. The strain to failure and tensile strength obtained from the slow strain rate studies for both alloys showed pronounced improvement due to corrosion inhibitor ability to mitigate SCC; the fractographic analysis showed a changed morphology with ductile overload as the primary failure mode instead of transgranular or intergranular cracking.

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7

Bander, F. "Multifuel Gas Turbine Propulsion for Naval Ships: Gas Turbine Cycles Implementing a Rotating Gasifier." Journal of Engineering for Gas Turbines and Power 107, no. 3 (July 1, 1985): 758–68. http://dx.doi.org/10.1115/1.3239798.

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The purpose of this paper is to investigate the possibilities of implementing a rotating gasifier to convert aero-derived gas turbines into multifuel ship propulsion units, thereby combining the advantages of lightweight and compact gas turbines with the multifuel characteristics of a rotating gasifier. Problems (and possible solutions) to be discussed are: (i) aerodynamic interaction between gas turbine and gasifier; (ii) attaining maximum energy productivity together with ease of control; (iii) corrosion and/or erosion of gas turbine components.

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Rocca, E., P. Steinmetz, and M. Moliere. "Revisiting the Inhibition of Vanadium-Induced Hot Corrosion in Gas Turbines." Journal of Engineering for Gas Turbines and Power 125, no. 3 (July 1, 2003): 664–69. http://dx.doi.org/10.1115/1.1456095.

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Since the 1970s, nothing substantially new has been published in the gas turbine community about the hot corrosion by vanadium and its inhibition, after the “inhibition orthodoxy” based on the formation of magnesium vanadate, was established. However, the experience acquired since the late 1980s with heavy-duty gas turbines burning ash-forming fuels in southern China, shows that the combustion of very contaminated fuels does not entail corrosion nor abundant ash-deposit on gas turbines buckets. Analyses of deposits collected from gas turbines fired with these crude oils showed that the ash-deposit contains a large amount of nickel. These new facts led to revisit the role played by nickel and envisage its possible inhibiting action against the vanadium-induced hot corrosion. A thorough review of the literature on the vanadium-induced corrosion have been carried out, and the study of the nickel effects with respect to magnesium effects on the ash deposit have been performed. Results show that nickel presents an interesting way to substitute magnesium for the inhibition of vanadium-induced hot corrosion. The advantages of nickel with respect to magnesium are to be efficient at alow Ni/V ratio, to produce less abundant, less adherent ash and to act, to some extent, as a self-cleaning agent for the blades of the turbine.

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Steinmetz, J., Pierre Steinmetz, and Anne Marie Huntz. "Corrosion Processes Related to Superalloys used in Gas Turbines." Solid State Phenomena 21-22 (January 1992): 223–76. http://dx.doi.org/10.4028/www.scientific.net/ssp.21-22.223.

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10

Goward, G. W. "Low-Temperature Hot Corrosion in Gas Turbines: A Review of Causes and Coatings Therefor." Journal of Engineering for Gas Turbines and Power 108, no. 2 (April 1, 1986): 421–25. http://dx.doi.org/10.1115/1.3239921.

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In about 1975 an apparently new form of hot corrosion attack of gas turbine airfoils was identified during low-power, low-metal-temperature operation of a marine gas turbine. The rate of this corrosion was substantially greater at about 700° C than that usually observed for sulfate-induced hot corrosion at 800° to 1000° C. The same type of hot corrosion has been subsequently reported to occur in ground-based gas turbines, and is similar in principle to fireside corrosion of boiler tubes. This paper presents a review of probable mechanisms of this so-called low-temperature hot corrosion, of test methods for its laboratory and rig simulation, and of coatings in use or in advanced development for protection of gas turbine airfoils operating in this corrosion regime.

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11

Fukudome, Takero, Sazo Tsuruzono, Tetsuo Tatsumi, Yoshihiro Ichikawa, Tohru Hisamatsu, and Isao Yuri. "Development of Silicon Nitride Components for Gas Turbine." Key Engineering Materials 287 (June 2005): 10–15. http://dx.doi.org/10.4028/www.scientific.net/kem.287.10.

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Silicon nitride is one of the most practical candidates for ceramic gas turbines. The SN282 is silicon nitride material developed by Kyocera for gas turbines. Several new technologies have been developed to achieve materialization of ceramic gas turbines, such as material, fabrication process, evaluation / analysis technology. Recent technology is focused on recession of silicon-based ceramics under combustion gas. Environmental Barrier Coatings (EBCs) are developed to suppress these recession. We have found rare-earth element silicate and yttrium stabilized zirconium oxide (YSZ) have high corrosion resistance to the combustion gas. These materials were applied to the ceramic gas turbine components. The components with EBCs were evaluated in the actual engine tests. We have confirmed that the EBCs effectively work for the recession resistance.

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12

Simms, N. J., A. Encinas-Oropesa, and John R. Nicholls. "Modelling the Development of Type I Hot Corrosion on Coated and Uncoated Single Crystal Superalloys." Materials Science Forum 595-598 (September 2008): 689–98. http://dx.doi.org/10.4028/www.scientific.net/msf.595-598.689.

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Gas turbines are critical components in the combined cycle power systems being developed to generate electricity from solid fuels, such as coal and biomass. The use of such fuels to produce fuel gases introduces the potential for significant corrosive and erosive damage to gas turbine blades and vanes. Single crystal superalloys have been developed for use with clean fuels but are now being deployed in industrial gas turbines. The performance of these materials, with coatings, has to be determined before they can be used with confidence in dirtier fuel environments. This paper reports results from a series of laboratory tests carried out using the ‘deposit replenishment’ technique to investigate the sensitivity of candidate materials to exposure conditions anticipated to cause type I hot corrosion in such gas turbines. The materials investigated have included the single crystal nickel-based superalloys CMSX-4 and SC2-B, both bare and with Pt-Al coatings. The exposure conditions within the laboratory tests have covered ranges of SOx (50 and 500 volume parts per million, vpm) and HCl (0 and 500 vpm) in air, as well as 4/1 (Na/K)2SO4 deposits, with deposition fluxes of 1.5, 5 and 15 5g/cm2/h, for periods of up to 500 hours at 900°C. Data on the performance of materials has been obtained using dimensional metrology: pre-exposure contact measurements and post-exposure measurements of features on polished cross-sections. These measurement methods allow distributions of damage data to be determined for use in the development of materials performance modelling. In addition, the types of damage observed have been characterised using standard optical and SEM/EDX techniques. The damage rates of the single crystal materials without coatings are too high for them to be used with confidence in gas turbines fired with gases derived from ‘dirty fuels’. Under the more severe combinations of gas composition, deposition flux and metal temperature, the corrosion rates of these materials with Pt-Al coatings are also excessive. The data produced from these tests has allowed the sensitivity of hot corrosion damage to changes in the exposure environment to be determined for the single crystal alloys and coating systems examined.

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13

McCreath, C. G., and J. F. G. Condé. "Hot corrosion in marine gas turbines – some aspects of mechanisms." Materials Science and Technology 2, no. 3 (March 1986): 324–26. http://dx.doi.org/10.1179/mst.1986.2.3.324.

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14

Grünling, H. W., and L. Singheiser. "Korrosionsschutzschichten in thermischen Maschinen / Corrosion-resistant coatings for gas turbines." Materials Testing 34, no. 7-8 (July 1, 1992): 220–23. http://dx.doi.org/10.1515/mt-1992-347-816.

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15

Day, William H. "A Partial History of Water-Cooled Gas Turbines." Mechanical Engineering 137, no. 09 (September 1, 2015): 76–77. http://dx.doi.org/10.1115/1.2015-sep-11.

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This article focuses on the work done at GE from 1960s to the early 1980s. GE funded the project of developing a full pressure/full temperature model of the same size. Test facilities were also built and run to gather data on potential problems such as: long term effects of partial channel water cooling on erosion, corrosion, and deposition; water supply, distribution and collection in the outer casing; materials testing with contaminated fuels. The results of the Electric Power Research Institute (EPRI) program were sufficiently encouraging that GE and EPRI decided to advocate a bigger project to the US Department of Energy to demonstrate the concept in utility size components. GE dropped work on water cooling in the early 1980s. Part of the reason was concern of instabilities in the boiling water.

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16

Grünling, H. W., H. Rechtenbacher, and Lorenz Singheiser. "Some Practical Aspects of Corrosion and Coatings in Utility Gas Turbines." Materials Science Forum 251-254 (October 1997): 483–504. http://dx.doi.org/10.4028/www.scientific.net/msf.251-254.483.

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17

Nicholls, J. R. "Advances in Coating Design for High-Performance Gas Turbines." MRS Bulletin 28, no. 9 (September 2003): 659–70. http://dx.doi.org/10.1557/mrs2003.194.

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AbstractSurface engineering is now a key materials technology in the design of future advanced gas-turbine engines. This article focuses on coating systems for hot-gas-path components, which can vary from low-cost aluminide diffusion coatings to the more exotic, and therefore expensive, thermal-barrier coatings. Available coating systems and their relative benefits are reviewed in terms of performance against manufacturing complexity and cost. Future trends in the design of environmental- and thermal-protection coatings are discussed, including the addition of multiple reactive elements, modified aluminide coatings, diffusion-barrier concepts, the design of “smart” corrosion-resistant coatings, and the development of structurally modified, low-thermal-conductivity thermal-barrier coatings.

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18

Spiro, C. L., S. G. Kimura, and C. C. Chen. "Ash Behavior During Combustion and Deposition in Coal-Fueled Gas Turbines." Journal of Engineering for Gas Turbines and Power 109, no. 3 (July 1, 1987): 325–30. http://dx.doi.org/10.1115/1.3240043.

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Chemical and physical transformations of coal ash during combustion and deposition in gas turbine environments have been studied. Extensive characterization of the coal-water mixture fuel and deposits obtained on deposition pins and turbine nozzle vanes has been performed. The behavior of alkali metals has been found to be much different from that for petroleum fuels, resulting in lower than expected deposition and probable reduced corrosion rates.

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19

Mu¨ller, M. "Estimation of risk of hot corrosion in gas turbines by thermodynamic modelling." Energy Materials 1, no. 4 (December 2006): 223–26. http://dx.doi.org/10.1179/174892406x173602.

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20

Kolkman, H. J. "Performance of Gas Turbine Compressor Cleaners." Journal of Engineering for Gas Turbines and Power 115, no. 3 (July 1, 1993): 674–77. http://dx.doi.org/10.1115/1.2906759.

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Deposits are regularly removed from compressor blades and vanes of installed jet engines and gas turbines by compressor washing. A compressor cleaner is sprayed into the compressor while operating at reduced or normal rpm. Recently developed compressor cleaners are claimed to be ecologically sound. In addition, many new compressor cleaners contain a corrosion inhibitor. The cleaning efficiency of eight (old and new) compressor cleaners was determined by means of simulated compressor washing of compressor blades that had become fouled in service. For the situation simulated, the cleaning efficiency of new, ecologically sound cleaners turned out to be poor as compared with old compressor cleaners. The corrosion inhibition offered by those cleaners that contain a corrosion inhibitor was found to be satisfactory.

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21

Nakamori, M., I. Kayano, Y. Tsukuda, Kunimasa Takahashi, and Taiji Torigoe. "Hot Corrosion and its Prevention in High Temperature Heavy Oil Firing Gas Turbines." Materials Science Forum 251-254 (October 1997): 633–40. http://dx.doi.org/10.4028/www.scientific.net/msf.251-254.633.

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22

Wong-Moreno,, A., and D. López-López,. "EROSION, CORROSION AND DEPOSITS IN GAS TURBINES BURNING HEAVY, HIGH SULPHUR FUEL OIL." Corrosion Reviews 14, no. 3-4 (December 1996): 265–96. http://dx.doi.org/10.1515/corrrev.1996.14.3-4.265.

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23

van Roode, M., J. R. Price, and C. Stala. "Ceramic Oxide Coatings for the Corrosion Protection of Silicon Carbide." Journal of Engineering for Gas Turbines and Power 115, no. 1 (January 1, 1993): 139–47. http://dx.doi.org/10.1115/1.2906668.

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Silicon carbide is currently used as a structural material for heat exchanger tubes and related applications because of its excellent thermal properties and oxidation resistance. Silicon carbide suffers corrosion degradation, however, in the aggressive furnace environments of industrial processes for aluminum remelting, advanced glass melting, and waste incineration. Adherent ceramic oxide coatings developed at Solar Turbines Incorporated, with the support of the Gas Research Institute, have been shown to afford corrosion protection to silicon carbide in a simulated aluminum remelt furnace environment as well as in laboratory-type corrosion testing. The coatings are also protective to silicon carbide-based ceramic matrix composites.

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24

Sawyer, J., R. J. Vass, N. R. Brown, and J. J. Brown. "Corrosion and Degradation of Ceramic Particulate Filters in Direct Coal-Fired Turbine Applications." Journal of Engineering for Gas Turbines and Power 113, no. 4 (October 1, 1991): 602–6. http://dx.doi.org/10.1115/1.2906283.

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High-temperature ceramic filters show considerable promise for efficient particulate removal from coal combustion systems. Advanced coal utilization processes such as direct coal-fired turbines require particulate-free gas for successful operation. This paper describes the various ceramic particulate filters under development and reviews the degradation mechanisms expected when operated in coal combustion systems.

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25

Nickel, H., D. Clemens, W. J. Quadakkers, and L. Singheiser. "Development of NiCrAlY Alloys for Corrosion-Resistant Coatings and Thermal Barrier Coatings of Gas Turbine Components." Journal of Pressure Vessel Technology 121, no. 4 (November 1, 1999): 384–87. http://dx.doi.org/10.1115/1.2883719.

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The demand for improved efficiency and power output of energy conversion systems has lead to an increase of gas inlet temperatures in modern land-based gas turbines. The resulting increase of component surface temperature leads to an enhanced oxidation attack of the blade coating, which, in stationary gas turbines, is usually of the MCrAlY (with M = Co and/or Ni) type. Considerable efforts have been made in the improvement of the high temperature properties of MCrAlY coatings by additions of minor alloying elements. In the present paper, the effect of systematic composition variations, especially yttrium, silicon, and titanium additions, on the protective properties of MCrAlY coatings are presented. The coatings were applied to a steel substrate by low-pressure plasma spraying. Then, free-standing MCrAlY-bodies were machined from the coating. Isothermal and cyclic oxidation tests were carried out in the temperature range 950°C–1100°C. The effect of systematic variation of titanium and silicon contents on oxidation and micro structural stability was studied by characterization of the coating and the corrosion products using light and electron optical microscopy and by secondary neutrals mass spectrometry (SNMS).

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26

Bradshaw, A., N. J. Simms, and J. R. Nicholls. "Hot corrosion tests on corrosion resistant coatings developed for gas turbines burning biomass and waste derived fuel gases." Surface and Coatings Technology 228 (August 2013): 248–57. http://dx.doi.org/10.1016/j.surfcoat.2013.04.037.

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27

Bolwell, Richard. "Understanding Royal Navy Gas Turbine Sea Water Lubricating Oil Cooler Failures When Caused by Microbial Induced Corrosion (“SRB”)." Journal of Engineering for Gas Turbines and Power 128, no. 1 (March 1, 2004): 153–62. http://dx.doi.org/10.1115/1.1926315.

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A managed program to review engine failures and take necessary preventative measures has been in place successfully in the Royal Navy since the introduction of gas turbines into service in the 1970s. One of the more prominent failure mechanisms with the Tyne RM1C and Spey SM1A engines has been the degradation of main line bearings accounting for 25% of all engines rejected. Historically, since the first recorded incident in March 1987, the failures pointed to poor performance of the bearings themselves. However, maintenance studies and recent analysis indicates that a vast proportion have occurred through previously unidentified chloride corrosion as a result of contamination of the lubricating oil system with salt water from the seawater lubricating oil cooler (SWLO cooler). Despite joint ownership of both engine variants with the Royal Netherlands Navy, there was no clear evidence until about five years ago to suggest why tube perforation was occurring. Indeed, the fact that failures have only occurred in Royal Navy service is an interesting twist to the problem. This paper summarizes the phenomenon of SWLO cooler corrosion caused by Microbial Induced Corrosion (principally Sulphate Reducing Bacteria—SRB). It highlights the conditions in which SRB occurs along with demonstrated prevention in Royal Navy gas turbine service through the combined efforts of maintenance and development of a new titanium tubestack. The fault finding and remedial recovery experience may well be of interest to operators of marine gas turbines, both naval and commercial, who use tube type heat exchangers, especially when operating or undertaking work in estuarial waters and nontidal basins or when undertaking littoral duties. This is a practical view of the issue from an operators perspective and while utilizing a wealth of research and technical data available on the subject, it relates the issues at hand to the particular corrosion problem and is not intended as an introduction into organic chemistry.

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28

Baiamonte, Lidia, Cecilia Bartuli, Francesco Marra, Annamaria Gisario, and Giovanni Pulci. "Hot Corrosion Resistance of Laser-Sealed Thermal-Sprayed Cermet Coatings." Coatings 9, no. 6 (May 28, 2019): 347. http://dx.doi.org/10.3390/coatings9060347.

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Hot corrosion affects the components of diesel engines and gas turbines working at high temperatures, in the presence of low-melting salts and oxides, such as sodium sulfate and vanadium oxide. Thermal-sprayed coatings of nickel–chromium-based alloys reinforced with ceramic phases, can improve the hot corrosion and erosion resistance of exposed metals, and a sealing thermal, post-treatment can prove effective in reducing the permeability of aggressive species. In this study, the effect of purposely-optimized high-power diode laser reprocessing on the microstructure and type II hot corrosion resistance of cermet coatings of various compositions was investigated. Three different coatings were produced by high velocity oxy-fuel and was tested in the presence of a mixture of Na2SO4 and V2O5 at 700 °C, for up to 200 h: (i) Cr3C2–25% NiCr, (ii) Cr3C2–25% CoNiCrAlY, and (iii) mullite nano–silica–60% NiCr. Results evidenced that laser sealing was not effective in modifying the mechanism, on the basis of the hot corrosion degradation but could provide a substantial increase of the surface hardness and a significant decrease of the overall coating material consumption rate (coating recession), induced by the high temperature corrosive attack.

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29

Mudgal, Deepa, Pawan K. Verma, Surendra Singh, and Satya Prakash. "High Temperature Degradation of Co Based Superalloy in Incinerator Environment." Advanced Materials Research 585 (November 2012): 542–46. http://dx.doi.org/10.4028/www.scientific.net/amr.585.542.

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Degradation by high temperature oxidation and hot corrosion is the main failure mode of components in the hot section of gas turbines, boilers, industrial waste incinerators, metallurgical furnaces and petrochemical installations etc. Corrosive environment is because of the usage of wide range of fuel containing large amount of Cl and S together with the volatile alkali metals such as K and Na which leads to the degradation of material. To obviate this problem, superalloy Superco 605 has been studied in air as well as in molten salt environment at 900°C for 100cycles. Weight change measurements were taken by a digital electronic weighing balance having accuracy of 1 mg after each cycle (heating at 900°C for 1 hr. and subsequently cooling in air for 20 min.) which was used to determine the kinetics of corrosion. The oxide scales formed on the surface of the superalloy were characterized by various techniques such as FESEM, EDAX and XRD. It was found that superco 605 shows good oxidation resistance in air at 900°C but poor corrosion resistance in simulated incinerator environment.

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30

Harada, Yoshio. "Fuel Additives as a Corrosion Inhibitor for use Oil Firing Boilers and Gas Turbines." CORROSION ENGINEERING 35, no. 12 (1986): 718–31. http://dx.doi.org/10.3323/jcorr1974.35.12_718.

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31

Bolt, N. "High temperature corrosion in modern thermal power generation : gas turbines, high efficiency boilers, IGCC." Le Journal de Physique IV 03, no. C9 (December 1993): C9–741—C9–749. http://dx.doi.org/10.1051/jp4:1993977.

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32

Seljak, Tine, Brane Širok, and Tomaž Katrašnik. "Advanced fuels for gas turbines: Fuel system corrosion, hot path deposit formation and emissions." Energy Conversion and Management 125 (October 2016): 40–50. http://dx.doi.org/10.1016/j.enconman.2016.03.056.

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Goward, G. W., and L. W. Cannon. "Pack Cementation Coatings for Superalloys: A Review of History, Theory, and Practice." Journal of Engineering for Gas Turbines and Power 110, no. 1 (January 1, 1988): 150–54. http://dx.doi.org/10.1115/1.3240078.

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Nickel and cobalt-base superalloy blades and vanes in the hot sections of all gas turbines are coated to enhance resistance to hot corrosion. Pack cementation aluminizing, invented in 1911, is the most widely used coating process. Corrosion resistance of aluminide coatings can be increased by modification with chromium, platinum, or silicon. Chromium diffusion coatings can be used at lower temperatures. Formation and degradation mechanisms are reasonably well understood and large-scale manufacturing processes for these coatings are gradually being automated. Pack cementation and related diffusion coatings serve well for most aircraft engine applications. The trend for industrial and marine engines is more toward the use of overlay coatings because of the greater ease of designing these to meet a wide variety of corrosion conditions.

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34

Strangman, T. E., and J. L. Schienle. "Tailoring Zirconia Coatings for Performance in a Marine Gas Turbine Environment." Journal of Engineering for Gas Turbines and Power 112, no. 4 (October 1, 1990): 531–35. http://dx.doi.org/10.1115/1.2906200.

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Zirconia coatings represent an advanced materials technology that offers significant durability and performance benefits for marine gas turbines. Thin zirconia coatings offer superior resistance to hot corrosion attack from fuel (sulfur, vanadium, and sodium) and air (sea salt) impurities present in marine engine environments. Thicker zirconia coatings reduce transient thermal stresses and heat transferred into air-cooled components. This paper describes the development of zirconia coatings, applied by the electron beam evaporation-physical vapor deposition process, that are tailored to provide superior durability in a marine engine environment.

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35

Luna Ramírez, A., J. Porcayo-Calderon, Z. Mazur, V. M. Salinas-Bravo, and L. Martinez-Gomez. "Microstructural Changes during High Temperature Service of a Cobalt-Based Superalloy First Stage Nozzle." Advances in Materials Science and Engineering 2016 (2016): 1–7. http://dx.doi.org/10.1155/2016/1745839.

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Superalloys are a group of alloys based on nickel, iron, or cobalt, which are used to operate at high temperatures (T> 540°C) and in situations involving very high stresses like in gas turbines, particularly in the manufacture of blades, nozzles, combustors, and discs. Besides keeping its high resistance to temperatures which may approach 85% of their melting temperature, these materials have excellent corrosion resistance and oxidation. However, after long service, these components undergo mechanical and microstructural degradation; the latter is considered a major cause for replacement of the main components of gas turbines. After certain operating time, these components are very expensive to replace, so the microstructural analysis is an important tool to determine the mode of microstructure degradation, residual lifetime estimation, and operating temperature and most important to determine the method of rehabilitation for extending its life. Microstructural analysis can avoid catastrophic failures and optimize the operating mode of the turbine. A case study is presented in this paper.

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Mishra, N. K., A. K. Rai, S. B. Mishra, and R. Kumar. "Hot Corrosion Behaviour of Detonation Gun Sprayed Stellite-6 and Stellite-21 Coating on Boiler Steel SAE 431 at 900°C." International Journal of Corrosion 2014 (2014): 1–4. http://dx.doi.org/10.1155/2014/146391.

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Hot corrosion is the serious problem in gas turbines, superheaters, and economizers of coal-fired boilers. It occurs due to the usage of wide range of fuels such as coal, oil, and so on at the elevated temperatures. Protective coatings on boiler steels are used under such environments. In the present investigation, Stellite-6 and Stellite-21 coatings have been deposited on boiler steel SAE 431 by detonation gun method. The hot corrosion performance of Stellite-6 and Stellite-21 coated as well as uncoated SAE 431 steel has been evaluated in aggressive environment of Na2SO4-82%Fe2(SO4)3under cyclic conditions at an elevated temperature of 900°C for total duration of 50 cycles. Thermogravimetric technique was used to approximate the kinetics of hot corrosion. Stellite-6 coating imparted better hot corrosion resistance than Stellite-21 coating in the given environment. Scanning electron microscopy was used to characterize the surface of hot corrosion products.

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37

Holcomb, Gordon R. "Steam Oxidation of Advanced Steam Turbine Alloys." Materials Science Forum 595-598 (September 2008): 299–306. http://dx.doi.org/10.4028/www.scientific.net/msf.595-598.299.

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Power generation from coal using ultra supercritical steam results in improved fuel efficiency and decreased greenhouse gas emissions. Results of ongoing research into the oxidation of candidate nickel-base alloys for ultra supercritical steam turbines are presented. Exposure conditions range from moist air at atmospheric pressure (650°C to 800°C) to steam at 34.5 MPa (650°C to 760°C). Parabolic scale growth coupled with internal oxidation and reactive evaporation of chromia are the primary corrosion mechanisms.

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38

Wright, I. G., and B. A. Pint. "Bond coating issues in thermal barrier coatings for industrial gas turbines." Proceedings of the Institution of Mechanical Engineers, Part A: Journal of Power and Energy 219, no. 2 (March 1, 2005): 101–7. http://dx.doi.org/10.1243/095765005x6836.

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Thermal barrier coatings are intended to work in conjunction with internal cooling schemes to reduce the metal temperature of critical hot gas path components in gas turbine engines. The thermal resistance is typically provided by a 100-250 μm thick layer of ceramic (most usually zirconia stabilized with an addition of 7–8 wt% of yttria), and this is deposited on to an approximately 50 μ thick, metallic bond coating that is intended to anchor the ceramic to the metallic surface, to provide some degree of mechanical compliance, and to act as a reservoir of protective scale-forming elements (Al) to protect the underlying superalloy from high-temperature corrosion. A feature of importance to the durability of thermal barrier coatings is the early establishment of a continuous, protective oxide layer (preferably α-alumina) at the bond coating—ceramic interface. Because zirconia is permeable to oxygen, this oxide layer continues to grow during service. Some superalloys are inherently resistant to high-temperature oxidation, so a separate bond coating may not be needed in those cases. Thermal barrier coatings have been in service in aeroengines for a number of years, and the use of this technology for increasing the durability and/or efficiency of industrial gas turbines is currently of significant interest. The data presented were taken from an investigation of routes to optimize bond coating performance, and the focus of the paper is on the influences of reactive elements and Pt on the oxidation behaviour of NiAl-based alloys determined in studies using cast versions of bond coating compositions.

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Heo, In Kang, Dong Hyun Yoon, and Jae Hoon Kim. "Low Cycle Fatigue Life Evaluation According to Temperature and Orientation in Nickel-Base Superalloy." Key Engineering Materials 814 (July 2019): 121–26. http://dx.doi.org/10.4028/www.scientific.net/kem.814.121.

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Components of gas turbines must be extremely resistant to high temperatures, high stresses, high-temperature corrosion, and erosive environments. The materials used in these environmental conditions are mainly nickel-based superalloys. In this study, the low-cycle fatigue of the nickel-based superalloy Inconel 792 was examined. The total strain range of a gas turbine between 760 °C and 870 °C was considered as the parameter representing the actual gas turbine operation. In addition, tests were performed using a trapezoidal waveform of the total strain to reflect the operation-stop conditions of a gas turbine with frequent shutdowns. The results of the fatigue test were compared with the Coffin–Manson method and energy method. The fractured surface was analyzed using a scanning electron microscope (SEM).

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Ozgurluk, Yasin, Kadir Mert Doleker, and Abdullah Cahit Karaoglanli. "Investigation of the effect of V2O5 and Na2SO4 melted salts on thermal barrier coatings under cyclic conditions." Anti-Corrosion Methods and Materials 66, no. 5 (September 2, 2019): 644–50. http://dx.doi.org/10.1108/acmm-12-2018-2042.

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Purpose Thermal barrier coatings (TBCs), which are used in high temperature applications of gas turbines, are damaged due to fuels and airborne minerals under working conditions. Stable zirconia coatings, which are usually used as topcoat materials in TBCs, are damaged by interacting at high temperatures with elements such as vanadium and sulfur from low quality fuels. The purpose of this paper is to see the failure mechanism of TBC systems after hot corrosion damages. Design/methodology/approach CoNiCrAlY metallic bond coatings of TBC samples were produced by cold gas dynamic spray method which is a new trend production method and stabilized zirconia ceramic top coating was produced by atmospheric plasma spray method. In total, 50% by weight of V2O5 and 50% Na2SO4 salt mixtures were placed on TBC samples and subjected to hot corrosion test at 1000°C. Findings Hot corrosion behaviors of TBC samples were examined by scanning electron microscopy, elemental mapping analysis, energy dispersive X-ray spectrometry analysis and X-ray diffraction analysis. TBC samples were damaged at the end of 12-h cycles. Originality/value The paper provides to understand the mechanism of hot corrosion of TBCs with cold sprayed metallic bond coat.

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Seaver, D. W., and A. M. Beltran. "Nickel-Base Alloy GTD-222, a New Gas Turbine Nozzle Alloy." Journal of Engineering for Gas Turbines and Power 115, no. 1 (January 1, 1993): 155–59. http://dx.doi.org/10.1115/1.2906670.

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This paper summarizes the key properties of GTD-222 (Wood and Haydon, 1989), a new cast nickel-base nozzle alloy developed by GE for use in land-based gas turbines. GTD-222 is being introduced as a replacement for FSX-414 in second and third-stage nozzles of certain machines. Presented in this paper are comparisons of the tensile, creep-rupture, and fatigue properties of GTD-222 versus FSX-414. In addition, the results of a long-term thermal stability study, high-temperature oxidation, and hot corrosion evaluation as well as weldability results will be discussed.

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Rocca, Emmanuel, Lionel Aranda, and Michel Molière. "Chemistry of Ash-Deposits on Gas Turbines Hot Parts: Reactivity of Nickel, Zinc and Iron Oxides in (Na, V, S) Molten Salts." Materials Science Forum 595-598 (September 2008): 169–76. http://dx.doi.org/10.4028/www.scientific.net/msf.595-598.169.

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When ash-forming oils or contaminated distillate oils are used as fuels in land-based, marine or aero gas turbines, the hot gas path components, mainly the partition vanes and the blades of the expansion turbine are subjected to the deposition of slags that are corrosive at high temperature due to their low liquidus temperature. This hot corrosion process - if not properly inhibited - entails a dramatic life reduction of the hot gas path parts. MgO is a traditional, efficient inhibitor. Recently, it has been found that NiO also suppresses the corrosiveness of the (Na,S,V) melts by trapping vanadium in a refractory vanadate (Ni3V2O8); this compound is friable and does not tend to accumulate on turbine blades. The use of inhibitors entails losses in both machine performance and availability. Moreover, other metals can interfere with the inhibition process. In particular, zinc and iron are often inadvertently introduced in gas turbines fuels during their transportation or storage and they can significantly interact with nickel. This paper distinguishes the interactions between NiO on one hand and both ZnO and Fe2O3 on the other hand in the general complex chemistry of ash. The thermochemical study of (Na,S,V) melts in presence of Ni confirms that nickel is a good "trapper" of vanadium oxide at high temperature. However, they also show that nickel can react with iron to form the very stable ferrite NiFe2O4 and a low melting point vanadate phase. On the contrary, the presence of zinc affects to a lesser extent the reactivity of NiO versus V2O5 despite the formation of Ni1-xZnxO solid solutions.

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Mazalov, P. B., D. I. Suhov, E. A. Sulyanova, and I. S. Mazalov. "HEAT-RESISTANT COBALT-BASED ALLOYS." Aviation Materials and Technologies, no. 3 (2021): 3–10. http://dx.doi.org/10.18577/2713-0193-2021-0-3-3-10.

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Cobalt-based alloys are widely used for manufacturing of various components of gas turbine engines and gas turbines such as vanes and combustion chambers both in wrought state and as cast parts. They have been designed for improving the heat resistance due to solid solution and carbide-strengthening mechanisms. In order to obtain satisfactory oxidation resistance and hot corrosion resistance cobalt-based alloys are doped with sufficient amount of chromium (above 15 % wt.). Recently additive manufacturing has started to use cobalt-based alloys. The paper considers the features of the structure of high-temperature cobalt-based alloys and their application in various branches of industry.

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Sulzer, Sabin, Magnus Hasselqvist, Hideyuki Murakami, Paul Bagot, Michael Moody, and Roger Reed. "The Effects of Chemistry Variations in New Nickel-Based Superalloys for Industrial Gas Turbine Applications." Metallurgical and Materials Transactions A 51, no. 9 (June 22, 2020): 4902–21. http://dx.doi.org/10.1007/s11661-020-05845-7.

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Abstract Industrial gas turbines (IGT) require novel single-crystal superalloys with demonstrably superior corrosion resistance to those used for aerospace applications and thus higher Cr contents. Multi-scale modeling approaches are aiding in the design of new alloy grades; however, the CALPHAD databases on which these rely remain unproven in this composition regime. A set of trial nickel-based superalloys for IGT blades is investigated, with carefully designed chemistries which isolate the influence of individual additions. Results from an extensive experimental characterization campaign are compared with CALPHAD predictions. Insights gained from this study are used to derive guidelines for optimized gas turbine alloy design and to gauge the reliability of the CALPHAD databases.

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Langston, Lee S. "Gems of Turbine Efficiency." Mechanical Engineering 136, no. 09 (September 1, 2014): 76–77. http://dx.doi.org/10.1115/9.2014-sep-9.

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This article discusses the use of turbine single-crystal blades in gas turbines. Single-crystal turbine blades were first used in military engines on Pratt’s F100 engine, which powered the F16 and F15 fighter aircrafts. Their first commercial use was on P&WA’s JT9D-7R4 engine, which received FAA certification in 1982, powering Boeing’s 767 and the Airbus A310. In jet engines, single-crystal turbine airfoils have proven to have as much as nine times more relative life in terms of creep strength and thermal fatigue resistance and over three times more relative life for corrosion resistance, when compared to equiaxed crystal counterparts. Modern high turbine inlet temperature jet engines with long life would not be possible without the use of single-crystal turbine airfoils. By eliminating grain boundaries, single-crystal airfoils have longer thermal and fatigue life, are more corrosion resistant, can be cast with thinner walls, and have a higher melting temperature. These improvements all contribute to higher gas turbine thermal efficiencies.

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Bradshaw, A., N. J. Simms, and J. R. Nicholls. "Development of hot corrosion resistant coatings for gas turbines burning biomass and waste derived fuel gases." Surface and Coatings Technology 216 (February 2013): 8–22. http://dx.doi.org/10.1016/j.surfcoat.2012.10.047.

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Saunders, S. R. J. "Correlation of Laboratoryand In-Service Corrosion Behaviour of Uncoated and Coated Superalloy Components for Gas Turbines." Surface Engineering 1, no. 3 (January 1985): 179–86. http://dx.doi.org/10.1179/sur.1985.1.3.179.

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Coen-Porisini, F., R. Saiu, F. Dos Santos Marques, and F. Bregani. "Protective effect of coatings on the corrosion behaviour of Ni based superalloys in gas turbines atmospheres." Le Journal de Physique IV 03, no. C9 (December 1993): C9–569—C9–578. http://dx.doi.org/10.1051/jp4:1993960.

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Hsu, L. L. "Total corrosion control for industrial gas turbines: High temperature coatings and air, fuel and water management." Surface and Coatings Technology 32, no. 1-4 (November 1987): 1–17. http://dx.doi.org/10.1016/0257-8972(87)90094-6.

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Stephenson, D. J., J. R. Nicholls, and P. Hancock. "The interaction between corrosion and erosion during simulated sea salt compressor shedding in marine gas turbines." Corrosion Science 26, no. 10 (January 1986): 757–67. http://dx.doi.org/10.1016/0010-938x(86)90061-2.

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Journal articles on the topic 'Gas-turbines – Corrosion'

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