Development of coatings for protection in specific high temperature environments

Metallic and intermetallic coatings are widely used in jet engines and land-based gas turbines for oxidation and corrosion protection in the hotter parts of the engines. However there is a significant number of industrial processes where the use of protective coatings at high temperatures could contribute to a significant extension of life-time or an increase in operation temperature and thus efficiency. Examples of such industries are incineration and gasification of waste, biomass and coal, chemical process industries and petrochemical plants where highly aggressive environments are encountered containing species of e.g. carbon, chlorine, sulphur, vanadium or alcalines. Since most of these process environments contain only very low oxygen partial pressures or exhibit high concentrations of extremely aggressive compounds, the conventional, uncoated materials come to their limits. In recent years in laboratory work a number of new types of coatings have been developed for high-temperature applications which include diffusion coatings, overlay coatings and nanotechnological approaches for sealing porosity. In the paper the background of this development and the thermodynamic fundamentals are discussed together with some more recent solutions based on synergistic effects of multi-element coatings. Some results of performance tests of these coatings in sulfidizing, carburizing, chloridizing and vanadate environments will be presented. At the end conclusions can be drawn on the suitability of the different types of coatings for their specific applications. (c) 2006 Elsevier B.V. All rights reserved.