An in-situ formed ceramic/alloy/ceramic sandwich barrier to resist elements interdiffusion between NiCrAlY coating and a Ni-based superalloy

doi:10.1016/j.jmst.2020.09.002

Abstract

Abstract:

NiCrAlY coatings are widely applied on various alloy components to enhance oxidation and/or corrosion resistance at high temperatures. However, elements interdiffusion occurs between them due to composition difference. Although various diffusion barriers (DBs) are reported, this problem is still far from completely solved as most ceramic barriers suffer from poor adherence, while the metallic barriers play a limited role. In this study, NiCrAlY coating was deposited onto a second-generation single-crystal superalloy by arc ion plating. A novel simple method is provided to address elements interdiffusion. By pre-oxidation at a moderate temperature, a thin scale of Ni(Co)O forms at the alloy surface. It transforms to be an alumina/NiCoCr alloy/alumina sandwich by an in-situ reaction with the overlaying NiCrAlY coating and the alloy substrate at high service temperatures, which offers good barrier ability in conjunction with strong adhesion. In the presence of such an alumina/alloy/alumina DB, the NiCrAlY coating provides high resistance to oxidation and scale spallation for the alloy substrate.

Key words: Superalloys, NiCrAlY coating, High-temperature oxidation, Elements interdiffusion, Diffusion barrier

Cean Guo, Feng Zhou, Minghui Chen, Jinlong Wang, Shenglong Zhu, Fuhui Wang. An in-situ formed ceramic/alloy/ceramic sandwich barrier to resist elements interdiffusion between NiCrAlY coating and a Ni-based superalloy[J]. J. Mater. Sci. Technol., 2021, 70: 1-11.

Figures/Tables 10

Fig. 1. X-ray diffraction (XRD) patterns of the DD6 superalloy before and after pre-oxidation at 700 °C for 5 h.

Fig. 2. (a) Surface, and (b) cross-sectional microstructures of the DD6 alloy after pre-oxidation at 700 °C for 5 h.

Fig. 3. TEM bright-field image at places “I” and “II” (indicated in Fig. 2(b)), and the corresponding element mappings of area “I”.

Fig. 4. Interfacial microstructures between the NiCrAlY coating and the superalloy substrate that was (a) without pre-oxidation, (b) pre-oxidized at 700 °C for 5 h.

Fig. 5. Oxidation kinetics of the NiCrAlY and SDB + NiCrAlY coatings at 1100 °C.

Fig. 6. Surface morphologies after oxidation at 1100 °C in the air for 200 h of the (a) NiCrAlY coating, (b) SDB + NiCrAlY coating, and (c) EDS analysis at spallation area in (a).

Fig. 7. Cross-sectional microstructures at the alloy/coating interface after oxidation at 1100 °C for 200 h: (a) NiCrAlY coating, (b) SDB + NiCrAlY coating, and (c) enlarged view of the area indicated in (b).

Fig. 8. EPMA mappings at the interface between the DD6 alloy and the SDB + NiCrAlY coating after 200 h of exposure at 1100 °C.

Fig. 9. Schematic diagram showing formation process of the alumina/NiCoCr alloy/alumina sandwich: (a) the original two-phase alloy structure before pre-oxidation, (b) a thin Ni(Co)O scale formed on the alloy surface after pre-oxidation, and (c) sandwich developed at the alloy/coating interface on service at high temperatures.

Fig. 10. Standard state Gibbs free energies of formation of NiO, CoO, FeO, Cr2O3, SiO2 and Al2O3 as a function of temperature per mol O2.

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