Neutron diffraction residual stress analysis of thermal sprayed thick coatings for hardfacing applications

In the current transition towards NewZero 2050, the current fossil fuel-based power plants are being used with higher flexibility due to the intermittent nature of wind and solar renewable energy sources, posing components to excessive stress causing failures and downtime. We have developed a new Stellite 6 coating for power plant boilers that is exceptionally thick (1 mm) for the technique it has been produced with (thermal spray). Therefore, we propose to investigate the through-thickness residual stress profile of this coating, to better understand its relation with microhardness and role in early failure, potentially enhancing components lifetime and contributing to enable the transition to NetZero. Engin-X and the resolution and accuracy of neutron scattering will yield the high-quality data that can enable our research.