Thermal and Erosive Performance of HVOF Coatings for Thermowell Protection in High-Temperature Oil and Gas Applications

Produktinformationen

M.Sc. Alexandre Maier Eurich, alexandre_me91@hotmail.com; Anderson Becker, anderson.becker@lactec.com.br; M.Sc. Irene Bida de Araújo, irene.araujo@lactec.com.br; Dr. Igor Giacomelli Zanella, igor.zanella@lactec.com.br; Dr. Anderson Marenda Pukasiewicz, anderson.pukasiewicz@gmail.com; 

https://doi.org/10.53192/ITSC2026583

The performance of High-Velocity Oxy-Fuel (HVOF) sprayed coatings is strongly influenced by the feedstock powder characteristics and deposition conditions. This study evaluates the mechanical, erosive, and thermal behavior of Cr₃C₂-based and binary Cr₃C₂/WC HVOF coatings for thermowell protection in high-temperature oil and gas applications. Two Cr₃C₂–NiCr coatings and one Cr₃C₂/WC–NiCu coating were deposited and compared with AISI 304 stainless steel. Microstructural analysis revealed dense coatings with good interlamellar cohesion, although differences in porosity and thickness were observed depending on the powder manufacturing route. Slurry jet erosion tests demonstrated that all HVOF coatings outperformed the AISI 304 substrate, with the coating exhibiting the highest indentation fracture toughness showing the lowest erosion rate, despite higher porosity levels. Thermal analyses by DSC and DDSC indicated that all coatings maintain structural stability up to approximately 800 °C, with no abrupt phase transformations. The results highlight the dominant role of indentation fracture toughness over hardness and porosity in governing slurry erosion resistance, supporting the suitability of HVOF coatings for thermowell protection in harsh service conditions.

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Erscheinungsdatum

März 2026

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