Persona: Muelas Gamo, Raúl
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Instituto Nacional de Técnica Aeroespacial
El Instituto Nacional de Técnica Aeroespacial es el Organismo Público de Investigación (OPI) dependiente del Ministerio de Defensa. Además de realizar actividades de investigación científica y de desarrollo de sistemas y prototipos en su ámbito de conocimiento, presta servicios tecnológicos a empresas, universidades e instituciones.
El INTA está especializado en la investigación y el desarrollo tecnológico, de carácter dual, en los ámbitos de la Aeronáutica, Espacio, Hidrodinámica, Seguridad y Defensa.
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Muelas Gamo
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Publicación Restringido HVOF-Deposited WCCoCr as Replacement for Hard Cr in Landing Gear Actuators(Springer Nature Link, 2011-10-05) Agüero, Alina; Camón, F.; García de Blas, Javier; del Hoyo Gordillo, Juan Carlos; Muelas Gamo, Raúl; Santaballa, A.; Ulargui, S.; Vallés, P.WCCoCr coatings deposited by HVOF can replace hard Cr on landing gear components. Powders with two different WC particle sizes (micro and nano-) and geometries have been employed to study the effects on the coating’s properties. Moreover, coatings produced employing two sets of parameters resulting in high and low flame temperatures have been evaluated. Minor differences in microstructure and morphology were observed for the two powders employing the same spraying parameters, but the nano-sized powder exhibited a higher spraying efficiency. However, more significant microstructural changes result when the low- and high-energy spray parameters are used. Moreover, results of various tests which include adhesion, wear, salt fog corrosion resistance, liquid immersion, and axial fatigue strength, indicate that the coatings produced with high-energy flame are similar in behavior. On the other hand, the nanostructured low-energy flame coating exhibited a significantly lower salt fog corrosion resistance.Publicación Restringido Long exposure steam oxidation testing and mechanical properties of slurry aluminide coatings for steam turbine components(Elsevier, 2005-11-21) Osgerby, Steve; Pastor Muro, Ana; Agüero, Alina; Muelas Gamo, RaúlImportant efforts to develop new steels or to protect high creep strength steels in order to allow operation of steam turbines at 650 °C are being carried out world-wide to increase efficiency. Within the European Project “SUPERCOAT” (Coatings for Supercritical Steam Cycles), work has been concentrated in the development of coatings to withstand 50,000–100,000 h of operation at 650 °C under high pressure steam. Aluminide coatings on ferritic–martensitic steels produced by applying an Al slurry followed by a diffusion heat treatment, have shown to be protective at 650 °C under steam for at least 32,000 h of laboratory steam exposure under atmospheric pressure. Although the “as diffused” coatings present through thickness cracks, these do not propagate during exposure to steam or thermal cycling and no new cracks seem to develop. Moreover, no changes in residual stresses could be observed after thermal cycling. Microstructural characterization of samples at different periods of exposures has been carried out by SEM-EDS and XRD. The principal mechanism of coating degradation is loss of Al at the surface due to inwards diffusion. Microhardness as well as Young's modulus and fracture strength were measured using well established techniques. The coatings show reasonable ductility (∼1.6%) when stressed in tension between room temperature and 400 °C which further increases at higher temperatures providing evidence that the coatings should withstand the mechanical conditions likely to be encountered in service.Publicación Restringido Performance of HIPIMS deposited CrN/NbN nanostructured coatings exposed to 650 °C in pure steam environment(Elsevier, 2016-05-20) Hovsepian, P.; Ehiasarian, A. P.; Purandare, Y. P.; Biswas, B.; Pérez, F. J.; Lasanta, M. I.; De Miguel, M. T.; Illana, A.; Juez Lorenzo, M.; Muelas Gamo, Raúl; Agüero, AlinaIn the current work, 4 μm thick CrN/NbN coating utilising nanoscale multilayer structure with bi-layer thickness of Δ = 2.9 nm has been used to protect 9 wt% Cr steels such as P92 widely used in steam power plants. The uniquely layered coatings have a combination of nitrides of chromium and niobium which are not only resistant to aqueous corrosion and corrosion-erosion and have excellent tribological properties, but also have oxidation resistance in dry air up to a temperature of 850 °C. The novel High Power Impulse Magnetron Sputtering (HIPIMS) deposition technology has been used to deposit CrN/NbN with enhanced adhesion (critical load of scratch adhesion LC2 = 80 N) and a very dense microstructure as demonstrated by Transmission Electron Microscopy (TEM) imaging. These superior coating properties are achieved due to the unique high metal ion content (up to 90%) in the HIPIMS plasma, which allows particle acceleration and trajectory control by external electrical and magnetic fields thus delivering highly energetic material flux on the condensing surface. P92 bare and coated samples were oxidised at 650 °C in 100% steam atmosphere up to 2000 h, in order to simulate the future operation conditions of steam turbines employed in power plants. The oxidation kinetics was evaluated by mass gain measurements. Under these conditions CrN/NbN provided reliable protection of the P92 steel. The paper also discusses the effect of growth defects and high temperature crack formation analysed by Scanning Electron Microscopy and Focused Ion Beam-Scanning Electron Microscopy techniques (SEM and FIB-SEM, respectively) on the high temperature corrosion resistance in pure steam atmosphere thus revealing the coatings potential failure mechanisms.Publicación Restringido Laboratory corrosion testing of coatings and substrates simulating coal combustion under a low NOx burner atmosphere(Wiley online library, 2013-07-02) Agüero, Alina; Gutiérrez del Olmo, Marcos; Muelas Gamo, Raúl; Plana, Daniel; Román, A.; Hernández, M.It is certainly a difficult task to evaluate new materials and coatings to be used for boilers in power plants, as conditions are extremely complex, comprising a highly erosive environment, high temperature, highly corrosive gases, and reactive deposits. In particular, early catastrophic failures, as well as higher degradation rates have been observed on different power plant boiler components when operating under atmospheres containing low levels of oxygen. These atmospheres are typical of low NOx burners, and can be more corrosive than normal oxidizing conditions. The presence of a sulfidizing atmosphere as well as ash deposits present in boilers, are in part responsible of this accelerated damage. In this work, testing under a low oxygen atmosphere has been carried out on T22 and P92 uncoated and coated specimens. The atmosphere was equal to that measured in a Spanish coal-fired power plant (ENDESA, Compostilla, León) and the test temperature was 580 °C. Tested coatings were slurry applied aluminides, as well as two HVOF sprayed coatings including a commercially deposited Cr2C3NiCr, and a newly developed Cr2O3-Cr composite coating. The specimens were covered with ash (taken from the plant) prior to testing. After testing, the uncoated substrates exhibited high thickness oxides with some sulfide inclusions whereas all tested coatings were very protective. Exposed samples of T22 tubes employed in the Compostilla power plants were analyzed and compared with the corresponding specimens tested in the laboratory. In both cases, the scales contained Fe3O4 and FeS but the sulfide content was significantly higher in the scale formed in the plant. Moreover, ash particles were found embedded in the both scales.Publicación Restringido Cyclic oxidation and mechanical behaviour of slurry aluminide coatings for steam turbine components(Elsevier, 2007-04-02) Agüero, Alina; Muelas Gamo, Raúl; Gutiérrez del Olmo, Marcos; Van Vulpen, R.; Osgerby, Steve; Banks, J. P.The excellent steam oxidation resistance of iron aluminide coatings on ferritic steels at 650 °C has been demonstrated both by laboratory tests and field exposure. These coatings are formed by the application of an Al slurry followed by diffusion heat treatment at 700 °C for 10 h. The resulting microstructure is mostly composed of Fe2Al5 on top of a much thinner FeAl layer. This coating exhibits perpendicular cracks due to thermal expansion mismatch between coating and substrate. However, these stress relieving cracks do not seem to have an effect on the mechanical properties of the substrate. Cyclic oxidation, creep resistance and TMF testing of these coatings at 650 °C indicate excellent performance.Publicación Restringido HVOF coatings for steam oxidation protection(Wiley online library, 2008-05-29) Agüero, Alina; Muelas Gamo, Raúl; González, Vanessa; Centro de Astrobiología del Instituto Nacional de Técnica Aeroespacial y CSIC, MDM-2017-0737In the context of the European project ‘Coatings for Supercritical Steam Cycles’ (SUPERCOAT), the use of steam oxidation resistant coatings on currently available ferritic materials with high creep strength but poor oxidation resistance was investigated in order to allow increase in the operating temperature of steam power plants from 550 to 650 °C. Among the explored coating techniques for this application, chosen on the basis of being potentially appropriate for coating steam turbine components, High Velocity Oxy Fuel (HVOF) thermal spray has resulted in one of the most successful techniques. Different alloyed materials such as FeCrAl, NiCrSiFeB, FeAl, NiCr and FeCr have been deposited, optimized and tested under flowing steam at 650 °C. Characterization of as deposited and tested samples by metallography, SEM-EDS and XRD was carried out. Some of these coatings form protective pure chromium or aluminium oxides exhibiting excellent behaviour for at least 15 000 h of exposure, whereas others form less stable complex mixed oxides which nevertheless grow at considerably slower rates than the oxides formed on uncoated P92 (9 wt% Cr ferritic steel).Publicación Restringido Corrosion Resistance of Novel Coatings on Ferritic Steels for Oxycombustion–Supercritical Steam Boilers: Preliminary Results(Springer Nature Link, 2015-07-23) Agüero, Alina; Baraibar, Ignacio; González, Vanessa; Muelas Gamo, Raúl; Plana, Daniel; European Commission; Ministerio de Economía y Competitividad (MINECO)Increasing the efficiency of coal fired steam power plants is an important contribution towards clean coal power. In fact, new ferritic steels are expected to withstand 325 bar and 650 °C. Moreover, in order to facilitate CO2 capture oxygen can be used instead of air for combustion (oxycombustion) so that no NOX emissions are produced. Boiler components, such as superheater tubes, are exposed to both steam and fireside corrosion and at higher temperatures, ferritic steels corrode at very fast rates under both atmospheres. A solution can be found in the use of protective coatings, a number of which, applied by techniques capable of depositing said coatings both on the inner and outer surfaces of tubes, are being studied within nationally and European funded projects. In particular, two new Ni and Cr modified aluminide coatings deposited on P92 by non-line-of-sight hybrid processes have been produced and the preliminary results of on-going laboratory testing, both under oxycombustion model atmospheres as well as under pure steam at 650 °C are promising, in particular those exhibited by the Cr enriched aluminide coating. Moreover, results obtained in a pilot oxycombustion boiler operated by CIUDEN in Leon, Spain are also shown.Publicación Restringido Comparison between field and laboratory steam oxidation testing on aluminide coatings on P92(Wiley online library, 2011-01-12) Agüero, Alina; González, V; Gutiérrez del Olmo, Marcos; Knödler, R; Straub, S; Muelas Gamo, Raúl; Centro de Astrobiología del Instituto Nacional de Técnica Aeroespacial y CSIC, MDM-2017-0737Steam oxidation has become an important issue for steam power plants as operating temperatures increase from the current 550 to 600–650 °C. For the last 10 years several groups have been carrying out steam oxidation testing of both uncoated substrates and coatings in the laboratory. On the other hand, field testing results are very scarce. In this paper, a comparison of laboratory steam oxidation testing with field test results carried out by Alstom at the Kraftwerk Westfalen power station located in Hamm, Germany will be presented. Both slurry deposited aluminide coatings and uncoated P92 steel have been included in the study. Under steam (atmospheric pressure) and isothermal conditions in the laboratory at 650 °C, spallation of oxides formed on ferritic steels occurs after significantly longer time when compared to exposure to real operating conditions. Oxide spallation results in serious damage in steam power plants by obstructing heat exchanger tubes, erosion of valves and turbine blades, etc. Moreover, the thickness of the oxide scales formed under field testing conditions is significantly higher after similar exposure. On the other hand, aluminide coated P92, which exhibit thickness through cracks, have shown to be stable in the laboratory for up to 60 000 h at 650 °C under steam, without evidence of crack propagation. However, field test results indicate that some degree of crack propagation occurs but without causing substrate attack up to 21 700 h of exposure. Moreover, the aluminium oxide observed in both laboratory and field tested specimens is different.Publicación Restringido Overview of steam oxidation behaviour of Al protective oxide precursor coatings on P92(Taylor and Francis online, 2016-03-04) Agüero, Alina; Gutiérrez del Olmo, Marcos; Muelas Gamo, Raúl; Spiradek Hahn, K.Future designs for steam power plants are expected to operate at 625–750°C, at which the candidate ferritic/martensitic steels exhibit insufficient steam oxidation resistance. Al-based coatings constitute an alternative to prevent or reduce oxidation. For over 50 years this type of coating has been applied on blades and vanes made of Ni- and Co-based alloys used in the hot section gas of turbines which operate at temperatures higher than 900°C. For these coatings, the mechanism of protection from high-temperature oxidation, is based on the formation and maintenance of a thin layer of dense α-Al2O3. Many articles have been written about the nature, formation and failure mechanism of oxide precursor coatings, under air, at over 900°C. [1–6] However, very little is known regarding alumina scales formed under pure steam at lower temperatures, which is the expected scenario for new steam power plants. This paper covers a recapitulation of the behaviour of Al-based protective oxides formed on coatings with various compositions under steam at 650°C, including new data relative to the formation of said oxides under steam and the microstructure of samples exposed to steam for 70 000 h. It has been shown that on Al containing coatings, such as diffusion Fe aluminides and FeCrAls, alumina forms under steam at 650°C. Provided that a critical content of Al is maintained underneath the scale, Al2O3 is very stable, surpassing 70 000 h under steam at 650°C, without evidence of spallation (testing is still ongoing). The industry target for coatings in this cases is 100 000 h. In turn, the critical Al content depends on the coating's Cr content, and if the oxidation takes place at temperatures of 900°C or higher, under air. However, under steam, alumina phases formation and transformations are different: at 650°C χ-Al2O3 forms initially, and appears to slowly transform unto α-Al2O3. General considerations regarding the stability of protective oxides formed under steam as a function of the composition of the subjacent material will be provided.Publicación Restringido Microstructural Evolution of Slurry Fe Aluminide Coatings during High Temperature Steam Oxidation(Trans Tech Publications, 2008-09-15) Agüero, Alina; Spiradek, Krystina; Höfinger, S; Gutiérrez del Olmo, Marcos; Muelas Gamo, RaúlSlurry iron aluminide coatings are very resistant to steam oxidation at 600-650º C. These coatings can be used to protect new generation Ultra Super Critical (USC) steam power plant ferritic/martensitic steel components. The microstructure of the initially deposited coating changes as a function of time, mainly due to coating-substrate interdiffusion, going from mostly Fe2Al5 to FeAl, causing the precipitation of AlN in those substrates containing a minimum content of N and moreover, developing Kirkendall porosity at the coating-substrate interface. Steam oxidation at 650º C causes the formation of a protective thin layer of hexagonal χ-Al2O3 phase along with some α- and γ-Al2O3 after the first few hours of exposure. However, despite the relatively low temperature, and after several thousands hours the protective layer was mostly composed of α-Al2O3. A study of the evolution of the microstructure of slurry aluminide coatings deposited on P92 and exposed to steam at 650º C has been carried out by scanning and transmission electron microscopy and X ray diffraction.
