it is now generally accepted practice to apply coatings to
components in fossil fuel energy processes to protect against
surface degradation processes such as wear, oxidation, corrosion
and erosion.The nanostructured thin TiAlN and AlCrN coatings
deposited by PVD technique and the conventional thick TiAl and AlCr
coatings deposited by Plasma Spraying and further gas nitrided;
were selected for the present work. After conducting the various
experiments on uncoated and coated alloys (total 16
substrate-coating combinations along with the bare alloys) in lab
and in actual industrial environment which includes the
characterization of the nanostructured and conventional TiAlN and
AlCrN coatings on selected Fe-based alloys and their behavior when
exposed to high temperature oxidation studies in air, molten salt
environment and in a coal fired boiler of a thermal power plant,
erosion studies in simulated coal-fired boiler environment; the
coating-substrate combinations which are found successful in
protecting the substrates from oxidation, hot corrosion, erosion
and wear are proposed to provide thermal insulation, corrosion and
wear resistance to the components in chemical process plants
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