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Nanostructured Coatings by Pulsed Plasma Processing for Alloys used in Coal-Fired Environments

Award Information
Agency: Department of Energy
Branch: N/A
Contract: DE-FG02-05ER86249
Agency Tracking Number: 79811T05-I
Amount: $97,550.00
Phase: Phase I
Program: STTR
Solicitation Topic Code: 15b
Solicitation Number: DE-FG01-O4ER04-33
Solicitation Year: 2005
Award Year: 2005
Award Start Date (Proposal Award Date): N/A
Award End Date (Contract End Date): N/A
Small Business Information
5555 Northwest Parkway
San Antonio, TX 78249
United States
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: Yes
Principal Investigator
 Madhavrao Govindaraju
 (210) 582-3312
Business Contact
 Susan Wright
Title: Ms.
Phone: (210) 582-3252
Research Institution
 Southwest Research Institute
 R. B Kalmbach
6220 Culebra Road
San Antonio, TX 78238
United States

 (210) 522-2261
 Domestic Nonprofit Research Organization

79811 Coal-fired power plants are a significant part of the nation¿s power generating capacity, currently accounting for more than 55 percent of the country¿s total electricity production. Efficient and profitable operation of coal-fired power plants requires higher steam temperatures, necessitating the use of advanced alloys such as ferritic and austenitic alloys. A major concern in using these advanced materials is their poor corrosion and oxidation resistance in fossil energy environments. The high temperatures and the presence of sulfur and water vapor can lead to severe oxidation, sulfidization, and carburizing problems in tubing, piping, and valves in fossil fuel-fired boilers. This project will develop protective coatings for these ferritic and austenitic steels used in coal-fired environments. In particular, an innovative pulsed-plasma fused coating technology will be developed, which uses slurry precursors in the preparation of durable nanostructured coatings of titanium aluminide coatings on Fe- and Ni-based alloys. In Phase I, a prototype of the pulsed plasma coating system will be constructed. Coated samples will be fabricated and then characterized by chemical, physical, structural, and microscopical techniques. The performance of the pulsed plasma-coated samples will be compared with uncoated samples in simulated furnace environment. Commercial Applications and other Benefits as described by the awardee: The new coating technology should have a significant impact on the electrical utility industry by saving the materials costs involved in replacing corroded tubes. Other benefits include reduced downtime, increased efficiency in power generation, and a reduced probability of catastrophic failure. The technology is versatile and could be extended to materials or components used in other industrial applications.

* Information listed above is at the time of submission. *

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