Erosion behaviour of alumina ceramic coating on mild steel by the modified composition of phosphate binder

Abstract

The Pulverizer pipe made of mild steel had erosion failure due to coal dust impacting, thus its service life also reduces. The ceramic coating overlay on the surface of mild steel is one of the appropiate ways to protect the mild steel from erosion. This research is aimed to perform a ceramic coating over the surface of the mild steel using a dipping method to improve its erosion resistance by using the alumina-phosphate ceramic coating. The coating layer is formed by the reaction between monoaluminum phosphate (MAP) as a binder and Al2O3 particles. It transforms into berlinite phase when heated at an elevated temperature. The observation is carried out with the variation of the MAP binder composition Al:P 25:75, 28:72, 30:70 and the Al2O3/MAP slurry is given at 40/60. Scanning electron microscopy is used to characterize the coating morphology. X-ray diffraction is applied to investigate the ceramic coating phases. The gas erosion jet measures erosion resistance of the ceramic coating. From the test result, it can be concluded that the binder composition influenced the erosion behaviour of alumina ceramic coating, the binder with Al:P (30:70) showed the erosion resistance increasing four times compared to the condition without coating.