In Geo-Coat project, laboratory-based tests in simulated geothermal conditions have been performed. Corrosion resistance, erosion wear, erosion-corrosion wear, sliding wear, contact angle and cost performance have been evaluated for each material/substrate combination selected for the project. Systems prepared (i.e. deposited and manufactured for coatings and MMCs respectively) on each substrate have then been scored and ranked together with the state-of-the-art wrought alloy currently employed for the specific application.
| Application Area ID | Application Areas | Coating Selected By The Project | Coating Composition (Mol. Ratio) | Coating Composition (wt.%) | Deposition/Consolidation Process |
|---|---|---|---|---|---|
| S1 | Pipes & Casings | LC_HEA2 | CoCrFeNiMo 0.85 (HEA2) | Co19.19 Cr19.19 Fe19.19 Ni19.19 Mo26.56 | Laser Cladding (LC) |
| S2 | Valve stem/turbine (blades) | LC_HEA2 | CoCrFeNiMo 0.85 (HEA2) | Co19.19 Cr19.19 Fe19.19 Ni19.19 Mo26.56 | Laser Cladding (LC) |
| S3 | Turbine rotors (+diaphragms) | LC_HEA2 | CoCrFeNiMo 0.85 (HEA2) | Co19.19 Cr19.19 Fe19.19 Ni19.19 Mo26.56 | Laser Cladding (LC) |
| S4 | Turbine blades | LC_HEA2 | CoCrFeNiMo 0.85 (HEA2) | Co19.19 Cr19.19 Fe19.19 Ni19.19 Mo26.56 | Laser Cladding (LC) |
| S5 | Pump impellers | HIP_Ti64+10%TiB₂ | - | Ti6AI4V 90 TiB₂10 | Hot Isostatic Pressing (HIP) |
| S6 | Heat exchanger tubes | ENP_LP (Low Phosphorus) | Ni-P/Ni-P-PTFE | - | Electroless Nickel Plating (ENP) |
This table illustrates the coating system ranking for Valve stem/turbine (blades)
| Application area | SOA/Coating types | Corrosion and erosion | Mechanical and tribological | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Erosion-corrosion | Corrosion penetration (max.μm) | Stress corrosion cracking (SCC) | Permeability | Pitting | Cracks | Erosion-wear | 3PB tilt angle (°) | Wear rate | Coefficient of friction (CoF) | Nano-hardness | Adhesion | ||||
| (mm/y) | Flow through corrosion (7 days) | Static corrosion (60 days) | (g/min) | Pre-corr. | Post-corr. | x10³ mm³ N⁻¹ m⁻¹ | (-) | (HV) | (N) | ||||||
| S2 | Grade 630 | N/A | 7 | 3 | N/A | - | - | - | N/A | N/A | N/A | 2.77 | 0.83 | 484 | N/A |
| S2 | LC_HEA2 | 5.2 | 0.1 | 0.1 | N/A | - | - | - | 0.0116 | 13 | 12 | 1.74 | 0.46 | 747 | >200 |
| S2 | HVOF_CA2 | 15.3 | 127* | 110 | N/A | + | - | + | 0.059 | 13 | 12 | 0.26 | 0.52 | 1293 | 65 |
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