Role of Carbide-Based Thermal-Sprayed Coatings to Prevent Failure for Boiler Steels: A Review

Modern boilers operating at high temperatures and pressures face a constant battle against wear, corrosion, and oxidation. These harsh conditions can rapidly degrade boiler steel components, leading to costly downtime and safety concerns. Carbide- and nitride-based thermal-sprayed coatings emerge as a powerful solution, extending the lifespan of boiler components and enhancing overall boiler efficiency. This review paper aims to provide an overview on various surface modification techniques. Thereafter, various erosion, corrosion and oxidation problems in boiler steels are discussed. Then, the role of carbide- and nitride-based thermal-sprayed coating to prevent failure of boiler steels is discussed. Subsequently, the distinct ways to improve the performance of carbide-based coatings are explored. Finally, the effects of post-treatment on the microstructure, mechanical and tribological properties are summarized. Overall, this research provides a comprehensive understanding of how carbide-based thermal-sprayed coatings contribute to the protection of boiler steels against various failure mechanisms.