J. Mater. Sci. Technol. ›› 2021, Vol. 88: 258-269.DOI: 10.1016/j.jmst.2021.01.068
Yumeng Nia,b, Fan Zhangc, Demian I. Njokua, Yingjie Yua,b, Jinshan Pand, Meijiang Menga, Ying Lia,e,*(
)
Received:2020-10-29
Revised:2021-01-07
Accepted:2021-01-24
Published:2021-03-19
Online:2021-03-19
Contact:
Ying Li
About author:* Corrosion and Protection Division, Shenyang NationalLaboratory for Materials Science, Institute of Metal Research, Chinese Academy ofSciences, Shenyang, 110016, China.E-mail address: liying@imr.ac.cn (Y. Li).Yumeng Ni, Fan Zhang, Demian I. Njoku, Yingjie Yu, Jinshan Pan, Meijiang Meng, Ying Li. Corrosion mechanism of CuAl-NiC abradable seal coating system—The influence of porosity, multiphase, and multilayer structure on the corrosion failure[J]. J. Mater. Sci. Technol., 2021, 88: 258-269.
| Spray parameters | Value and unit |
|---|---|
| Spray distance | 140 mm |
| Plasma gas (Ar) flow rate | 90 L/min |
| H2 flow rate | 10 L/min |
| Arc current | 550 A |
| Voltage | 60 V |
| Powder feed rate | 40 g/min |
| Carrier gas (N2) flow rate | 4 L/min |
Table 1 Plasma spray process parameters for the NiAl bond layer.
| Spray parameters | Value and unit |
|---|---|
| Spray distance | 140 mm |
| Plasma gas (Ar) flow rate | 90 L/min |
| H2 flow rate | 10 L/min |
| Arc current | 550 A |
| Voltage | 60 V |
| Powder feed rate | 40 g/min |
| Carrier gas (N2) flow rate | 4 L/min |
| Spray parameters | Value and unit |
|---|---|
| Spray distance | 160 mm |
| O2 flow rate | 1.3 m3/h |
| C2H2 flow rate | 1.0 m3/h |
| Powder feed rate | 60 g/min |
Table 2 Flame spray process parameters for the CuAl-NiC top layer.
| Spray parameters | Value and unit |
|---|---|
| Spray distance | 160 mm |
| O2 flow rate | 1.3 m3/h |
| C2H2 flow rate | 1.0 m3/h |
| Powder feed rate | 60 g/min |
Fig. 1. XRD patterns of (a) the as-sprayed CuAl-NiC top layer and (b) the NiAl bond layer before immersion.
Fig. 2. Cross-sectional morphology of the CuAl-NiC ASC system before the immersion.
Fig. 3. EDS mapping results of the cross-section of the CuAl-NiC ASC system.
Fig. 4. Cross-sectional morphologies of the corrosion products formed inside the CuAl-NiC ASC system with different immersion time in 5 wt.% NaCl solution: (a) 8 h; (b) 72 h; (c) 480 h; (d) 1440 h.
Fig. 5. EDS mapping results of the corrosion products formed in the NiAl bond layer and on the surface of the substrate after 60 days of immersion.
Fig. 6. The morphology of the detached surface after 60 days of immersion in 5 wt.% NaCl solution.
Fig. 7. EDS mapping results of the corrosion products formed on the detached surface after 60 days of immersion.
Fig. 8. Distribution of the pore diameter for the CuAl-NiC top layer with different immersion times in 5 wt.% NaCl solution.
| Immersion time (h) | Porosity (%) | The most probable pore diameter (nm) |
|---|---|---|
| 0 | 12.03 | 553.1 |
| 8 | 8.38 | 433.6 |
| 72 | 12.04 | 6234.9 |
| 480 | 22.68 | 9051.8 |
| 1440 | 31.27 | 11311.9 |
Table 3 The porosity and the most probable pore diameter of the CuAl-NiC top layer.
| Immersion time (h) | Porosity (%) | The most probable pore diameter (nm) |
|---|---|---|
| 0 | 12.03 | 553.1 |
| 8 | 8.38 | 433.6 |
| 72 | 12.04 | 6234.9 |
| 480 | 22.68 | 9051.8 |
| 1440 | 31.27 | 11311.9 |
Fig. 9. XRD analysis of (a) the CuAl-NiC top layer and (b) the NiAl bond layer before and after 60 days of immersion.
Fig. 10. OCP results for the separated CuAl-NiC top layer, the NiAl/substrate, the substrate, and the complete CuAl-NiC ASC system in 5 wt.% NaCl solution.
Fig. 11. Potentiodynamic polarization curves of the separated CuAl-NiC top layer, the separated NiAl bond layer, and the substrate.
| Ecorr (V/SCE) | icorr (×10-8 A cm-2) | |
|---|---|---|
| The separated CuAl-NiC top layer | -0.45 | 142.2 |
| The separated NiAl bond layer | -0.83 | 890.5 |
| The substrate | -0.31 | 2.9 |
Table 4 Ecorr and icorr of the separated CuAl-NiC top layer, the separated NiAl bond layer, and the substrate obtained from the polarization curves in Fig. 11.
| Ecorr (V/SCE) | icorr (×10-8 A cm-2) | |
|---|---|---|
| The separated CuAl-NiC top layer | -0.45 | 142.2 |
| The separated NiAl bond layer | -0.83 | 890.5 |
| The substrate | -0.31 | 2.9 |
Fig. 12. EIS data for the complete CuAl-NiC ASC system in 5 wt.% NaCl solution during the immersion: (a) the first stage; (b) the second stage; (c) the third stage; (d) the fourth stage.
Fig. 13. Equivalent circuits used for fitting the EIS data in Fig. 12(a)-(d): (a) equivalent circuit for the first and second stage; (b) equivalent circuit for the third and fourth stage. Rs: solution resistance; Rcp: corrosion product resistance; Rct: charge transfer resistance; R1: coating resistance; Zw: Warburg resistance; CPE: constant phase element used instead of capacitance.
| Rs (Ω cm2) | Rcp (Ω cm2) | Rct (Ω cm2) | Zw (Ω s-0.5 cm-2) | CPE1 (sα Ω-1 cm-2) | α1 | CPE2 (sα Ω-1 cm-2) | α2 | Σχ2 × 104 | |
|---|---|---|---|---|---|---|---|---|---|
| 2 h | 5.7 | 220 | 430 | 4.4 × 10-3 | 2.0 × 10-4 | 0.73 | 2.7 × 10-4 | 0.73 | 4.6 |
| 5 h | 5.9 | 490 | 970 | 4.8 × 10-3 | 1.2 × 10-4 | 0.79 | 1.9 × 10-4 | 0.69 | 3.0 |
| 8 h | 6.1 | 530 | 1700 | 4.9 × 10-3 | 1.2 × 10-4 | 0.80 | 2.0 × 10-4 | 0.61 | 1.7 |
| 12 h | 6.1 | 560 | 2300 | 5.1 × 10-3 | 1.2 × 10-4 | 0.80 | 2.1 × 10-4 | 0.53 | 4.2 |
Table 5 Fitting parameters of equivalent circuit elements corresponding to the first stage of immersion (Fig. 12(a)).
| Rs (Ω cm2) | Rcp (Ω cm2) | Rct (Ω cm2) | Zw (Ω s-0.5 cm-2) | CPE1 (sα Ω-1 cm-2) | α1 | CPE2 (sα Ω-1 cm-2) | α2 | Σχ2 × 104 | |
|---|---|---|---|---|---|---|---|---|---|
| 2 h | 5.7 | 220 | 430 | 4.4 × 10-3 | 2.0 × 10-4 | 0.73 | 2.7 × 10-4 | 0.73 | 4.6 |
| 5 h | 5.9 | 490 | 970 | 4.8 × 10-3 | 1.2 × 10-4 | 0.79 | 1.9 × 10-4 | 0.69 | 3.0 |
| 8 h | 6.1 | 530 | 1700 | 4.9 × 10-3 | 1.2 × 10-4 | 0.80 | 2.0 × 10-4 | 0.61 | 1.7 |
| 12 h | 6.1 | 560 | 2300 | 5.1 × 10-3 | 1.2 × 10-4 | 0.80 | 2.1 × 10-4 | 0.53 | 4.2 |
| Rs (Ω cm2) | Rcp (Ω cm2) | Rct (Ω cm2) | Zw (Ω s-0.5 cm-2) | CPE1 (sα Ω-1 cm-2) | α1 | CPE2 (sα Ω-1 cm-2) | α2 | Σχ2 × 104 | |
|---|---|---|---|---|---|---|---|---|---|
| 24 h | 6.3 | 540 | 2300 | 2.2 × 10-3 | 1.2 × 10-4 | 0.80 | 3.5 × 10-4 | 0.54 | 2.3 |
| 32 h | 6.3 | 450 | 2100 | 1.9 × 10-3 | 1.3 × 10-4 | 0.80 | 4.2 × 10-4 | 0.55 | 2.5 |
| 48 h | 6.3 | 440 | 1900 | 1.8 × 10-3 | 1.3 × 10-4 | 0.80 | 4.3 × 10-4 | 0.57 | 2.3 |
| 72 h | 7.7 | 260 | 2100 | 1.8 × 10-3 | 1.4 × 10-4 | 0.79 | 5.4 × 10-4 | 0.54 | 3.3 |
| 120 h | 7.6 | 280 | 2500 | 1.2 × 10-3 | 1.5 × 10-4 | 0.79 | 6.0 × 10-4 | 0.47 | 5.4 |
Table 6 Fitting parameters of equivalent circuit elements corresponding to the second stage of immersion (Fig. 12(b)).
| Rs (Ω cm2) | Rcp (Ω cm2) | Rct (Ω cm2) | Zw (Ω s-0.5 cm-2) | CPE1 (sα Ω-1 cm-2) | α1 | CPE2 (sα Ω-1 cm-2) | α2 | Σχ2 × 104 | |
|---|---|---|---|---|---|---|---|---|---|
| 24 h | 6.3 | 540 | 2300 | 2.2 × 10-3 | 1.2 × 10-4 | 0.80 | 3.5 × 10-4 | 0.54 | 2.3 |
| 32 h | 6.3 | 450 | 2100 | 1.9 × 10-3 | 1.3 × 10-4 | 0.80 | 4.2 × 10-4 | 0.55 | 2.5 |
| 48 h | 6.3 | 440 | 1900 | 1.8 × 10-3 | 1.3 × 10-4 | 0.80 | 4.3 × 10-4 | 0.57 | 2.3 |
| 72 h | 7.7 | 260 | 2100 | 1.8 × 10-3 | 1.4 × 10-4 | 0.79 | 5.4 × 10-4 | 0.54 | 3.3 |
| 120 h | 7.6 | 280 | 2500 | 1.2 × 10-3 | 1.5 × 10-4 | 0.79 | 6.0 × 10-4 | 0.47 | 5.4 |
| Rs (Ω cm2) | R1 (Ω cm2) | Rct (Ω cm2) | CPE1 (sα Ω-1 cm-2) | α1 | CPE2 (sα Ω-1 cm-2) | α2 | Σχ2 × 104 | |
|---|---|---|---|---|---|---|---|---|
| 240 h | 6.2 | 170 | 9900 | 4.3 × 10-4 | 0.67 | 6.2 × 10-4 | 0.53 | 4.7 |
| 312 h | 7.2 | 270 | 7100 | 7.9 × 10-4 | 0.80 | 1.0 × 10-3 | 0.58 | 1.7 |
| 360 h | 6.5 | 330 | 5600 | 8.3 × 10-4 | 0.80 | 9.6 × 10-4 | 0.55 | 1.3 |
| 480 h | 6.5 | 310 | 3700 | 9.2 × 10-4 | 0.79 | 1.0 × 10-3 | 0.60 | 1.2 |
Table 7 Fitting parameters of equivalent circuit elements corresponding to the third stage of immersion (Fig. 12(c)).
| Rs (Ω cm2) | R1 (Ω cm2) | Rct (Ω cm2) | CPE1 (sα Ω-1 cm-2) | α1 | CPE2 (sα Ω-1 cm-2) | α2 | Σχ2 × 104 | |
|---|---|---|---|---|---|---|---|---|
| 240 h | 6.2 | 170 | 9900 | 4.3 × 10-4 | 0.67 | 6.2 × 10-4 | 0.53 | 4.7 |
| 312 h | 7.2 | 270 | 7100 | 7.9 × 10-4 | 0.80 | 1.0 × 10-3 | 0.58 | 1.7 |
| 360 h | 6.5 | 330 | 5600 | 8.3 × 10-4 | 0.80 | 9.6 × 10-4 | 0.55 | 1.3 |
| 480 h | 6.5 | 310 | 3700 | 9.2 × 10-4 | 0.79 | 1.0 × 10-3 | 0.60 | 1.2 |
| Rs (Ω cm2) | R1 (Ω cm2) | Rct (Ω cm2) | CPE1 (sα Ω-1 cm-2) | α1 | CPE2 (sα Ω-1 cm-2) | α2 | Σχ2 × 104 | |
|---|---|---|---|---|---|---|---|---|
| 600 h | 6.7 | 320 | 5000 | 9.7 × 10-4 | 0.77 | 1.5 × 10-3 | 0.63 | 1.9 |
| 720 h | 6.1 | 340 | 4100 | 9.5 × 10-4 | 0.78 | 2.4 × 10-3 | 0.74 | 2.8 |
| 840 h | 6.9 | 550 | 2900 | 9.8 × 10-4 | 0.79 | 2.4 × 10-3 | 0.60 | 3.2 |
| 960 h | 6.9 | 550 | 3000 | 9.9 × 10-4 | 0.79 | 2.4 × 10-3 | 0.59 | 1.6 |
| 1200 h | 6.9 | 540 | 3000 | 1.0 × 10-3 | 0.78 | 2.5 × 10-3 | 0.59 | 1.5 |
| 1440 h | 7.1 | 520 | 2900 | 1.0 × 10-3 | 0.78 | 2.4 × 10-3 | 0.60 | 1.5 |
Table 8 Fitting parameters of equivalent circuit elements corresponding to the fourth stage of immersion (Fig. 12(d)).
| Rs (Ω cm2) | R1 (Ω cm2) | Rct (Ω cm2) | CPE1 (sα Ω-1 cm-2) | α1 | CPE2 (sα Ω-1 cm-2) | α2 | Σχ2 × 104 | |
|---|---|---|---|---|---|---|---|---|
| 600 h | 6.7 | 320 | 5000 | 9.7 × 10-4 | 0.77 | 1.5 × 10-3 | 0.63 | 1.9 |
| 720 h | 6.1 | 340 | 4100 | 9.5 × 10-4 | 0.78 | 2.4 × 10-3 | 0.74 | 2.8 |
| 840 h | 6.9 | 550 | 2900 | 9.8 × 10-4 | 0.79 | 2.4 × 10-3 | 0.60 | 3.2 |
| 960 h | 6.9 | 550 | 3000 | 9.9 × 10-4 | 0.79 | 2.4 × 10-3 | 0.59 | 1.6 |
| 1200 h | 6.9 | 540 | 3000 | 1.0 × 10-3 | 0.78 | 2.5 × 10-3 | 0.59 | 1.5 |
| 1440 h | 7.1 | 520 | 2900 | 1.0 × 10-3 | 0.78 | 2.4 × 10-3 | 0.60 | 1.5 |
Fig. 14. Schematic presentation of the corrosion process inside the CuAl-NiC ASC system.
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