火电机组通流部件抗蒸汽氧化涂层技术发展与展望Progress in the development of high temperature coatings for protection of power generation steam components
鲁金涛,黄锦阳,杨珍,袁勇
摘要(Abstract):
长期以来,火电机组蒸汽侧的氧化皮问题是导致锅炉堵管、爆管等事故的主要安全隐患,尤其是随着先进超超临界火电技术的发展,更高蒸汽参数下火电机组面临的氧化皮问题将更加严峻。高温涂层技术为解决这一问题开辟了新的方法和思路,不仅能够满足苛刻服役环境下耐热钢对抗高温蒸汽氧化性能的需求,还可释放耐热钢因抗氧化不足而降档使用的温限,在能源系统领域中具有巨大的应用潜能。简述了欧盟、美国及国内的多个超(超)临界火电机组通流部件抗蒸汽氧化涂层技术的研发计划,重点综述了当前抗蒸汽氧化涂层设计策略及使役性能研究进展,提出了制约铝化物涂层在火电机组规模化应用的基础研究和工程应用问题,展望了高温铝化物涂层技术服役于超超临界电站锅炉复杂材质耐热钢管的应用前景。
关键词(KeyWords): 超超临界;高温涂层;锅炉管;蒸汽氧化;铝化物涂层
基金项目(Foundation): 国家自然科学基金项目(52271070);; 中国华能集团有限公司总部科技项目(HNKJ20-H41,TA-20-TYK03)~~
作者(Author): 鲁金涛,黄锦阳,杨珍,袁勇
DOI: 10.19666/j.rlfd.202306351
参考文献(References):
- [1]中国华能集团有限公司.金属部件失效分析[C]//金属技术监督会议.金属技术监督会议论文集:2019年卷.西安:西安热工研究院有限公司,2019:67-264.China Huaneng Group Corporation.Failure analysis of boiler components[C].Proceedings of the Conference on Metal Technical Supervision:Vol.2019.Xi’an:Xi’an Thermal Power Research Institute Co.,Ltd.,2019:67-264.
- [2]WRIGHT I,DOOLEY R.Morphologies of oxide growth and exfoliation in superheater and reheater tubing of steam boiler[J].Materials at High Temperatures,2011,28(1):40-57.
- [3]王倩,王卫良,刘敏,等.超(超)临界燃煤发电技术发展与展望[J].热力发电,2021,50(2):1-9.WANG Qian,WANG Weiliang,LIU Min,et al.Development and prospect of(ultra) supercritical coalfired power generation technology[J].Thermal Power Generation,2021,50(2):1-9.
- [4]STRINGER J.Coatings in the electricity supply industry:past,present,and opportunities for the future[J].Surface and Coatings Technology,1998,108:1-9.
- [5]AGüERO A,GUTIéRREZ M,MUELAS R,et al.Overview of steam oxidation behaviour of Al protective oxide precursor coatings on P92[J].Surface Engineering,2018,34(1):30-39.
- [6]BOULESTEIX C,PEDRAZA F.Characterisation of aluminium diffusion coatings elaborated on austenitic stainless steels and on ferritic-martensitic steels[J].Surface and Coatings Technology,2018,339:27-36.
- [7]王心悦,辛丽,韦华,等.高温防护涂层研究进展[J].腐蚀科学与防护技术,2013,25(3):175-183.WANG Xinyue,XIN Li,WEI Hua,et al.Progress of hightemperature protective coatings[J].Corrosion Science and Protetion Technology,2013,25(3):175-183.
- [8]VISWANATHAN R,SARVER J,TANZOSH J M.Boiler materials for ultra-supercritical coal power plants-steam side oxidation[J].Journal of Materials Engineering and Performance,2006,15(3):255-274.
- [9]SANDSTR?M R.Coal power plant materials and life assessment:creep strength of austenitic stainless steels for boiler applications[M].Sawston:Woodhead Publishing,2014:127-146.
- [10]ZHANG N,ZHU Z,XU H,et al.Oxidation of ferritic and ferritic-martensitic steels in flowing and static supercritical water[J].Corrosion Science,2016,103:124-131.
- [11]张乃强.电站锅炉管氧化层在溶氧超临界水中生长机理的研究[D].北京:华北电力大学,2012:54-66.ZHANG Naiqiang.Research on oxide scale growth mechanism of boiler tube in power plant exposed to supercritical water with dissolved oxygen[D].Beijing:North China Electric Power University,2012:54-66.
- [12]石全强,刘坚,严伟,等.SIMP钢和T91钢在800℃的高温氧化行为[J].材料研究学报,2016,30(2):81-86.SHI Quanqiang,LIU Jian,YAN Wei,et al.High temperature oxidation behavior of SIMP steel and T91steel at 800℃[J].Chinese Journal of Materials Research,2016,30(2):81-86.
- [13]ZHANG D,LIU J,XUE Z,et al.Oxidation behavior of T92 steel with Ni Co Cr Al Y coating by EB-PVD[J].Surface and Coatings Technology,2014,252:179-185.
- [14]董猛,谢逍原,朱阳存,等.G115和T92钢表面Fe Al渗层制备及其抗高温水蒸汽氧化性能[J].材料热处理学报,2021,42(5):135-142.DONG Meng,XIE Xiaoyuan,ZHU Yangcun,et al.Preparation of Fe Al penetration layer on G115 and T92steel surfaces and its oxidation resistance to high temperature steam[J].Transactions of Materials and Heat Treatment,2021,42(5):135-142.
- [15]MATHIAZHAGAN P,KHANNA S.High temperature oxidation behavior of P91,P92 and E911 alloy steels in dry and wet atmospheres[J].High Temperature Materials and Processes,2011,30(1-2):43-50.
- [16]周永莉,鲁金涛,李浩,等.超(超)临界锅炉用18-8系奥氏体不锈钢阶段式氧化动力学特征研究[J].材料导报,2018,32(增刊2):389-393.ZHOU Yongli,LU Jintao,LI Hao,et al.Staged feature of oxidation kinetics of 18-8Cr austenitic stainless steel for ultra-supercritical boiler application[J].Materials Reports,2018,32(Suppl.2):389-393.
- [17]王江滨.超(超)临界锅炉Super304H不锈钢氧化特性研究[D].哈尔滨:哈尔滨工业大学,2016:32-41.WANG Jiangbin.Oxide behavor research of Super304Hfor (ultra) supercritical boiler[D].Harbin:Harbin Institute of Technology,2016:32-41.
- [18]刘晓,王海,朱忠亮,等.电站用奥氏体耐热钢HR3C与Sanicro25在超临界水中的氧化特性[J].中国腐蚀与防护学报,2020,40(6):529-538.LIU Xiao,WANG Hai,ZHU Zhongliang,et al.Oxidation characteristics of austenitic heat-resistant steel HR3C and Sanicro25 in supercritical water for power station[J].Journal of Chinese Society for Corrosion and protection,2020,40(6):529-538.
- [19]郑开云,亓安芳,王起江.三种700℃电站锅炉用抗蒸汽氧化性能评价[J].锅炉技术,2013,44(2):38-44.ZHENG Kaiyun,QI Anfang,WANG Qijiang.Evaluation of the steam oxidation resistance of three types of alloys for 700℃power plant boilers[J].Boiler Technology,2013,44(2):38-44.
- [20]杨珍,鲁金涛,谷月峰.高温合金GH 2984在750℃水蒸气中的氧化行为研究[J].稀有金属材料与工程,2017,46(4):1013-1019.YANG Zhen,LU Jintao,GU Yuefeng.Oxidation mechanism of GH 2984 alloy in pure steam at 750℃[J].Rare Metal Materials and Engineering,2017,46(4):1013-1019.
- [21]乐明,于在松,鲁金涛,等.喷丸对Inconel740H合金饱和蒸汽氧化行为影响[J].热力发电,2017,46(3):33-38.LE Ming,YU Zaisong,LU Jintao,et al.Effect of shot peening on saturated steam oxidation behavior of Inconel740H[J].Thermal Power Generation,2017,46(3):33-38.
- [22]倪一帆,杨昌顺,王苗苗.GH750和Haynes 282在750℃水蒸气中的氧化行为研究[J].动力工程学报,2021,41(7):596-601.NI Yifan,YANG Changshun,WANG Miaomiao.Oxidation behavior of GH750 and Haynes282 in steam at750℃[J].Journal of Chinese Society of Power Engineering,2021,41(7):596-601.
- [23]任秀敏,梁志远.高效超超临界机组用高温合金蒸汽氧化行为研究[J].有色金属工程,2019,9(12):1-8.REN Xiumin,LIANG Zhiyuan.Steam oxidation behavior of high temperature alloys for high efficiency ultrasupercritical units[J].Nonferrous Metals Engineering,2019,9(12):1-8.
- [24]袁勇,党莹樱,杨珍,等.700℃先进超超临界机组末级过热器用新型镍铁基高温合金的组织与性能[J].机械工程材料,2020,44(1):44-50.YUAN Yong,DANG Yingying,YANG Zhen,et al.Microstructure and properties of Ni-Fe-Base superalloy for 700℃advanced ultra supercritical unit final superheater[J].Materials for Mechanical Engineering,2020,44(1):44-50.
- [25]HOLCOMB G.Steam oxidation and chromia evaporation in ultrasupercritical steam boilers and turbines[J].Journal of the Electrochemical Society,2009,156:292-297.
- [26]YOUNG D,PINT B.Chromium volatilization rates from Cr2O3 scales into flowing gases containing water vapor[J].Oxidation of Metals,2006,66(3/4):137-153.
- [27]YU Y,LIU Z,ZHANG C,et al.Correlation of creep fracture lifetime with microstructure evolution and cavity behaviors in G115 martensitic heat-resistant steel[J].Materials science and Engineering A,2020,788:139468.
- [28]LI Y,WANG X.Strengthening mechanisms and creep rupture behavior of advanced austenitic heat resistant steel SA-213 S31035 for A-USC power plants[J].Materials Science and Engineering:A,2020,775:138991.
- [29]WRIGHT I,DOOLEY R.A review of the oxidation behaviour of structural alloys in steam[J].Metallurgical Reviews,2010,55(3):129-167.
- [30]鲁金涛,谷月峰.电站锅炉关键部件材料高温蒸汽氧化研究进展[J].中国腐蚀与防护学报,2014,34:19-26.LU Jintao,GU Yuefeng.High-temperature steam oxidation behavior of alloys used for key parts of the power plants boiler[J].Journal of Chinese Society for Corrosion and protection,2014,34:19-26.
- [31]YUAN J,WANG W,ZHU S,et al.Comparison between the oxidation of iron in oxygen and in steam at 650-750degrees C[J].Corrosion Science,2013,75:309-317.
- [32]CHANDRA-AMBHORN S,WONGPROMRAT P,THUBLAOR T,et al.Effect of water vapour on the high temperature oxidation of stainless steels[J].Solid State Phenomena,2020,300:107-134.
- [33]VISWANATHAN R,SARVER J,TANZOSH J M.Boiler materials for ultra-supercritical coal power plantssteamside oxidation[J].Journal of Materials Engineering&Performance,2006,15(3):255-274.
- [34]YAN J,ZHANG P,GU Y,et al.Oxide cracking behaviour of Cu-added 18%Cr-8%Ni austenitic alloy after steam oxidation[J].Corrosion Science,2020,169:108601.
- [35]张骏,蔡文河,杜双明,等.喷丸奥氏体耐热钢抗蒸汽氧化性的研究与使用现状[J].表面技术,2020,49(9):133-140.ZHANG Jun,CAI Wenhe,DU Shuangming,et al.Research and application status of steam oxidation resistance of shot peening austenitic heat-resistant steel[J].Surface Technology,2020,49(9):133-140.
- [36]王彩侠,贾建民,赵慧传,等.加热温度对奥氏体不锈钢管内壁喷丸处理效果的影响[J].热力发电,2011,40(12):87-91.WANG Caixia,JIA Jianmin,ZHAO Huichuan,et al.Influence of heating temperature upon shot-balsting treament on internal surface of austenitic stainless steel tubes[J].Thermal Power Generation,2011,40(12):87-91.
- [37]SCHEEFER M,KN?DLER R,SCARLIN B,et al.New oxidation-resistant coatings for steam power plants at 650℃[J].Materials and Corrosion,2015,56(12):907-915.
- [38]MEYER H,ERDMANN D,MOSER P,et al.Coal-fired power stations with steam temperatures up to 650℃[J].VGB Power Tech,2008,88:1-10.
- [39]KOSTER C.Steps on the path towards new coal-fired power plants-the VGB joint research programme KOMET650[J].Fuel&energy abstracts,2002,43(4):263-263.
- [40]VISWANATHAN R,COLEMAN K,SHINGLEDECKER J,et al.Materials for ultrasupercritical coal-fired power plant boilers[J].International Journal of Pressure Vessels and Piping,2006,83(11/12):778-783.
- [41]HACK H,STANKO G.Effects of fuel composition and temperature on fireside corrosion resistance of materials for advanced ultrasupercritical coal fired power plants[J].Energy Materials,2007,2(4):241-248.
- [42]VISWANATHAN R,HENRY F,Tanzosh J,et al.USprogram on materials technology for ultra-supercritical coal power plants[J].Journal of materials engineering and performance,2005,14(3):281-292.
- [43]黄锦阳,鲁金涛,张醒兴,等.火电机组过/再热器锅炉管内壁铝化物涂层研究(Ⅰ):涂层制备及组织结构[J].表面技术,2020,79:272-279.HUANG Jinyang,LU Jintao,ZHANG Xingxing,et al.Slurry aluminide coatings on boiler tubes for overheater/reheater(I):preparation and microstructure[J].Surface Technology,2020,79:272-279.
- [44]黄锦阳,钟强,黄浩刚,等.火电机组过/再热器锅炉管内壁铝化物涂层研究(Ⅲ):涂层部件实炉服役行为[J].表面技术,2021,50(7):328-336.HUANG Jinyang,ZHONG Qiang,HUANG Haogang,et al.Slurry aluminide coatings on boiler tubes for overheater/reheater application(III):field testing[J].Surface Technology,2021,50(7):328-336.
- [45]周永莉,鲁金涛,谷月峰.火电机组锅炉管表面改性技术研究现状[J].中国电机工程学报,2017,37(1):149-160.ZHOU Yongli,LU Jintao,GU Yuefeng.Research progress of surface modification on coal-fired power plant boiler tubes[J].Proceedings of the CSEE,2017,37(1):149-160.
- [46]李美栓.金属的高温腐蚀[M].北京:冶金出版社,2001:420-432.LI Meishuan.High temperature corrosion of metals[M].Beijing:Metallurgical Press,2001:420-432.
- [47]AGüERO A.Progress in the development of coatings for protection of new generation steam plant components[J].Energy Materials,2008,3(1):35-44.
- [48]SANZ J,GARCIA R,KOLARIK V,et al.Influence of the slurry thickness and heat treatment parameters on the formation of aluminium diffusion coating[J].Oxidation of Metals,2017,88(1):179-190.
- [49]XIANG Z,DATTA P.Pack aluminisation of low alloy steels at temperatures below 700℃[J].Surface and Coatings Technology,2004,184(1):108-115.
- [50]AGüERO A,MUELAS R,PASTOR A,et al.Long exposure steam oxidation testing and mechanical properties of slurry aluminide coatings for steam turbine components[J].Surface and Coatings Technology,2005,200(5/6):1219-1224.
- [51]SHEN M,ZHU S,WANG F.A general strategy for the ultrafast surface modification of metals[J].Nature Communications,2016,7(1):1-6.
- [52]SPECHT P,NEUMANN P.Fracture planes and toughness of stoichiometric Fe Al single crystals[J].Intermetallics,1995,3(5):365-368.
- [53]XIANG Z,DATTA P.Shot peening effect on aluminide diffusion coating formation on alloy steels at low temperatures[J].Scripta Materialia,2006,55(12):1151-1154.
- [54]蔡志刚,谢涛.锅炉管的高温腐蚀及渗铝防护[J].热力发电,1996(1):3-13.CAI Zhigang.XIE tao.High temperature corrosion of boiler tubes and their protection by aluminizing[J].Thermal Power Generation,1996(1):3-12.
- [55]HUANG J,LU J,ZHANG X,et al.Preparation and characterization of a slurry Al-Si coating on austenitic steel TP347H FG[J].Metallurgical and Materials Transactions A,2019,50(8):3776-3784.
- [56]AGüERO A,GONZáLEZ V,GUTIéRREZ M,et al.Comparison between field and laboratory steam oxidation testing on aluminide coatings on P92[J].Materials and Corrosion,2011,62(6):561-568.
- [57]AGüERO A,BARáIBAR I,GUTIéRREZ M,et al.Steam oxidation of aluminide-coated and uncoated TP347HFG stainless steel under atmospheric and ultrasupercritical steam conditions at 700℃[J].Coatings,2020,10(9):839-849.
- [58]ZHOU Y,LU J,SHEN M,et al.Low-temperature formation and steam oxidation of β-Fe Al coating on P92steel[J].Corrosion Science,2020,163:108227.
- [59]YANG Z,LU J,ZHANG P,et al.Oxidation performance and microstructural evolution of the slurry aluminide coating deposited on Super304H in steam at 600~650℃[J].Surface and Coatings Technology,2020,391:125700.
- [60]PEDRAZA F,BOULESTEIX C,PROY M,et al.Behavior of slurry aluminized austenitic stainless steels under steam at 650 and 700℃[J].Oxidation of Metals,2017,87(3/4):443-454.
- [61]BATES B,ZHANG Y,DRYEPONDT S,et al.Creep behavior of pack cementation aluminide coatings on Grade 91 ferritic-martensitic alloy[J].Surface and Coatings Technology,2014,240:32-39.
- [62]DRYEPONDT S,ZHANG Y,PINT B.Creep and corrosion testing of aluminide coatings on ferriticmartensitic substrates[J].Surface and Coatings.Technology,2006,201:3880-3884.
- [63]AGüERO A,MUELAS R,GUTIéRREZ M,et al.Cyclic oxidation and mechanical behaviour of slurry aluminide coatings for steam turbine components[J].Surface and Coatings Technology,2007,201:6253-6260.
- [64]HOU X,ZHANG H,SERAFFON M,et al.Steam oxidation and mechanical performance of a ferriticmartensitic steel with slurry aluminide coating[J].Materials and Corrosion,2020,71(8):1310-1320.
- [65]LU J,DANG Y,HUANG J,et al.Preparation and characterization of aluminide coating on Super304Hboiler tube by following heat treatment process[J].Surface and Coatings Technology,2019,37:97-105.
- [66]JIMENEZ J,FROMMEYER G.Creep behavior of intermetallic Fe-Al and Fe-Al-Cr alloys[J].Materials Science and Engineering:A,1996,220(1/2):93-99.
- [67]AGüERO A,MUELAS R,GUTIéRREZ M,et al.Cyclic oxidation and mechanical behaviour of slurry aluminide coatings for steam turbine components[J].Surface and Coatings Technology,2007,201(14):6253-6260.
- [68]GUO S,WANG Z,LU K.An aluminide surface layer containing lower-Al on ferritic-martensitic steel formed by lower-temperature aluminization[J].Journal of Materials science&Technology,2015,31(12):1268-1273.
- [69]PINT B,ZHANG Y,WALKER L,et al.Long-term performance of aluminide coatings on Fe-base alloys[J].Surface and Coatings Technology,2007,202:637-642.
- [70]BOULESTEIX C,KOLARIK V,PEDRAZA F.Steam oxidation of aluminide coatings under high pressure and for long exposures[J].Corrosion Science,2018,144:328-338.
- [71]XIANG Z D,DATTA P K.Pack aluminisation of low alloy steels at temperatures below 700℃[J].Surface and Coatings Technology,2004,184:108-115.
- [72]CHEN W,HE L,GUO Y.Effects of reactive element oxides on the isothermal oxidation of β-Ni Al coatings fabricated by spark plasma sintering[J].Surface and Coatings Technology,2019,15:322-331.
- [73]MENG X,YUWEN P,SHAO W.Cyclic oxidation behaviour of Co/Si co-doped β-Ni Al coating on nickel based superalloys[J].Corrosion Science,2018,133:112-119.
- [74]LU J,HUANG J,WANG J,et al.Long-term degradation behavior of slurry aluminide coating on Super304Hstainless steel at 650℃[J].Corrosion Science,2021,178:109054.
- [75]ZHAO Z,LU J,HUANG J,et al.A comprehensive investigation of phase evolution of Al-Si coating during the prolonged aging at 650℃[J].Corrosion Science,2021,189:109605.
- [76]MORRIS D,MUNOZ-MORRIS M A,CHAO J.Development of high strength,high ductility and high creep resistant iron aluminide[J].Intermetallics,2004,12(7/8/9):821-826.
- [77]AGüERO A,GUTIéRREZ M,MUELAS R,et al.Laboratory corrosion testing of coatings and substrates simulating coal combustion under a low NOx burner atmosphere[J].Materials&Corrosion,2014,65(2):149-160.
- [78]高压锅炉用无缝钢管:GB/T 5310-2017[S].上海:中国钢铁工业协会,2017:14-26.Seamless steel tubes and pipes for high-pressure boiler:GB/T 5310-2017[S].Shanghai:China Iron and Steel Association,2017:14-26.
- [79]DURHAM R,SINGHEISER L,QUADAKKERS W.Identification of degradation mechanisms in coatings for supercritical steam applications[J].Materials and corrosion,2008,59(5):402-408.
- [80]Standard specification for aluminum diffusion coating applied by pack cementation process:ASTM B875[S].West Conshocken:ASTM International,2018:1-3.
- [81]彭芳芳,朱国良,宋建新.超超临界机组用SUPER304H钢管国产化关键制造工艺的分析[J].动力工程学报,2008,28(5):803-806.PENG Fangfang,ZHU Guoliang,SONG Jianxin.Analysis of key manufacturing processes in domestic producing for SUPER304H steel tube applied in ultrasupercritical unit[J].Journal of Chinese Society of Power Engineering,2008,28(5):803-806.
- [82]DAK G,PANDEY C.A critical review on dissimilar welds joint between martensitic and austenitic steel for power plant application[J].Journal of Manufacturing Processes,2020,58:377-406.