• Corrosion Science and Technology
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• v.4 no.1
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• pp.23-28
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• 2005

Several plasma-sprayed ceramic coatings with two- and three-layers were characterized and tested for the application of cooling tube coatings of oxygen convert gas recovery system (OG cooling system) in the steel making plant. Thermal cycling tests using a torch heating with compressed air cooling were carried out and characterized before and after the tests. The effects of metallic bond coat as well as ceramic top coat were also studied. Possible failure mechanisms with low carbon steel substrate were assessed in term of microstructure, porosity, bond strength, thermal expansion coefficient, and the phase transformation. Finally, the results of field tests at the OG cooling system are presented and discussed their microstructural degradation. Test results have shown that three-layered coatings perform better than two-layered coatings.