In this work High Velocity Oxy-fuel (HVOF) thermal spray techniques, spraying process optimization, and characterization of coatings are reviewed. Different variants of the technology are described and the main differences in spray conditions in terms of particle kinetics and thermal energy are rationalized. Methods and tools for controlling the spray process are presented as well as their use in optimizing the coating process. It will be shown how the differences from the starting powder to the final coating formation affect the coating microstructure and performance. Typical properties of HVOF sprayed coatings and coating performance is described. Also development of testing methods used for the evaluation of coating properties and current status of standardization is presented. Short discussion of typical applications is done.

Large-scale use of biomass and recycled fuel is increasing in energy production due to climate and energy targets. A 40% cut in greenhouse gas emission compared to 1990 levels and at least a 27% share of renewable energy consumption are set in EU Energy Strategy 2030. Burning fuels with high content of corrosive species such as chlorine and heavy metals causes deterioration of boiler components, shortened lifetime, limited availability of a plant and hence higher maintenance and investment costs and lower thermal and economic efficiency. Coatings can be applied to protect the critical boiler components against high temperature corrosion. In this study, five thermal spray coatings were tested in an actual biomass co-firing boiler for 1300 h with a measurement probe. The coatings were analyzed after the exposure by metallographic means and scanning electron microscope/energy-dispersive X-ray spectroscope (SEM/EDX). The deposits formed on the specimens were analyzed by X-ray fluorescence. At 550 °C, the coatings showed excellent corrosion performance compared to reference material ferritic steel T92. At 750 °C, tube material A263 together with NiCr and NiCrTi had the highest corrosion resistance. To conclude, thermal spray coatings can offer substantial corrosion protection in biomass and recycled fuel burning power plants.

For improved efficiency and reduced emissions, the future power plants need to operate at high temperatures and pressures, which however are limited by the durability of conventional materials such as ferritic steels. Steam oxidation of a number of coatings (Al slurries, thermal spraying, chemical vapor deposition siliconizing, and nickel plating) has demonstrated the feasibility of coatings to improve oxidation resistance. Al slurry coatings combine good high-temperature oxidation resistance through the growth of an $Al2O3$ layer and the possibility to apply the coating on an industrial scale at moderate cost. This work aimed to test the oxidation performance of coatings and reference alloys in ultra-supercritical (USC) water. The tested materials included Al slurry coating on ferritic 9%Cr steel and nickel-based A263 substrates, and bulk P92, MARBN, and A263 alloys as reference specimens. Oxidation resistance was tested by exposure to flowing supercritical water (SCW) with 125 ppb dissolved oxygen at 650°C $(1202°F)/25MPa$ (3625 psi) up to 1000 hr.