Extending the Lifespan of HVAF Sprayed Hastelloy Coatings in H2S-Containing Environments by Using Sol-Gel Sealants
Y.S. Chiang (TU Delft - Mechanical Engineering)
Yaiza Gonzalez Gonzalez Garcia – Mentor (TU Delft - Team Yaiza Gonzalez Garcia)
F. Van Der Klift – Mentor (Shell Pernis)
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Abstract
In the petroleum industry, acidic corrosion is a frequent challenge, particularly in environments containing hydrogen sulfide (H₂S), where it accounts for approximately 18% of total failures. Among various forms of acidic corrosion, hydrogen-induced cracking (HIC) is most common in oil pipelines constructed from plate materials, leading to a decline in mechanical performance. Previous studies have shown that Hastelloy C276 coatings prepared by high velocity air fuel (HVAF) spraying can effectively prevent HIC. However, due to issues of high cost and coating porosity, extending the service life of HVAF sprayed Hastelloy C276 remains an open question. This study explores a sol-gel sealing strategy using SiO₂/ZrO₂ as the sealing material. HVAF Hastelloy C276 coated samples without sol–gel sealing served as the control group, while samples sealed with two and five layers formed the experimental groups. All samples were tested for mechanical strength, corrosion resistance, and HIC resistance. The results of these properties were compared to evaluate whether sol-gel sealing improves durability and how the number of layers influences coating performance.