Effects of oxide stringers on the β-phase depletion behaviour in thermally sprayed CoNiCrAlY coatings during isothermal oxidation

doi:10.1016/j.jmst.2019.11.018

Abstract

Abstract:

This paper details an investigation of the effects of oxide stringers on the β-phase depletion behaviour in thermally sprayed CoNiCrAlY coatings. Vacuum Plasma Sprayed (VPS) CoNiCrAlY coatings, which are free of oxide stringers, are used as the reference materials in comparison with High-Velocity Oxy-Fuel (HVOF) sprayed CoNiCrAlY coatings during isothermal oxidation at 1100 °C. An outer layer of spinel oxides and an inner layer of alumina are formed in the as-sprayed coatings, while only a single alumina scale is found in the heat-treated coatings. Less β-phase depletion occurred in the HVOF coatings than in the VPS coatings. It was found that the β phases tend to coalesce at the oxide stringers in the HVOF coatings, which is likely due to the internal oxide particles and stringers acting as short diffusion barriers to tie up the β phase and inhibit the β-phase depletion.

Key words: MCrAlY, β-Phase depletion, Oxidation, Diffusion

H. Chen, A. Rushworth. Effects of oxide stringers on the β-phase depletion behaviour in thermally sprayed CoNiCrAlY coatings during isothermal oxidation[J]. J. Mater. Sci. Technol., 2020, 45: 108-116.

Figures/Tables 17

Table 1 The nominal composition (wt%) of the as-received CoNiCrAlY powder.

Co	Ni	Cr	Al	Y
Bal.	31.7	20.8	8.1	0.5

Table 2 The HVOF spraying parameters.

N₂ gas flow rate (l/min)	4.3
O₂ gas flow rate (l/min)	890
Kerosene flow rate (ml/min)	470
Stoichiometry	98%
Powder feed rate (g/min)	64
Traverse speed, mm/s	1000
Number of passes	30

Table 3 The VPS spraying parameters.

Power (kW)	40
Current (A)	600
Voltage (V)	63
Ar flow (l/min)	50
Powder feed rate (g/min)	60
Traverse speed, mm/s	84
Number of passes	5

Fig. 1. CoNiCrAlY (Praxair CO-210-24) powder characterisation: (a) morphology of the powder particles, (b) cumulative particle size distribution and (c) powder cross-section.

Fig. 2. STEM elemental mapping of the powder particle cross-section showing the element distribution.

Fig. 3. Microstructure of as-sprayed HVOF (a and b) and VPS (c and d).

Fig. 4. Microstructure of heat-treated HVOF (a and b) and VPS (c and d).

Fig. 5. EDS mapping of heat-treated HVOF coating to show the dark-contrast particles are Al-rich oxides.

Fig. 6. Microstructure of as-sprayed HVOF (a and b) and VPS (c and d) coatings after 100 h oxidation at 1100 °C, showing the spinel and alumina scale formation and the remaining two-phase structure.

Fig. 7. EDS mapping analysis of the oxides formed in the as-sprayed CoNiCrAlY coating.

Fig. 8. Microstructure of heat-treated HVOF (a and b) and VPS (c and d) coatings after 100 h oxidation at 1100 °C, showing the alumina scale formation and the remaining two-phase structure.

Fig. 9. EDS mapping analysis of the oxides formed in the heat-treated CoNiCrAlY coating.

Fig. 10. Oxide thickness measurements against oxidation time at 1100 °C for as-sprayed HVOF and VPS coatings: (a) total oxide thickness, (b) spinel oxide thickness and (c) alumina scale thickness.

Fig. 11. Oxide thickness measurements against oxidation time at 1100 °C for heat-treated HVOF and VPS coatings. Only alumina is considered in the heat-treated conditions since very little spinel oxide is found.

Fig. 12. β-phase depletion against oxidation time in the as-sprayed HVOF and VPS coatings at 1100 °C.

Fig. 13. β-phase depletion against oxidation time in the heat-treated HVOF and VPS coatings at 1100 °C.

Fig. 14. The derived Al flux from oxide growth behaviour for HVOF and VPS coatings, (a) HVOF coating and (b) VPS coating.

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