On the rumpling mechanism in nanocrystalline coatings: Improved by reactive magnetron sputtering with oxygen

doi:10.1016/j.jmst.2022.04.054

Abstract

Abstract:

Surface rumpling is detrimental to high temperature protective coatings as it shortens their lifetime and leads to adhesion losses and unexpected corrosion degradation. The driving force and mass transport mechanism behind of rumpling remains to be clarified. In the present investigation, we subjected two types of nanocrystalline coating systems to avoid the influence of interdiffusion on rumpling study. One group was an ordinary nanocrystalline coating, and the other group was designed and prepared with trace oxygen by reactive magnetron sputtering. Systematic cyclic oxidation test at 1100 °C was also carried out. Results show the ordinary nanocrystalline coating oxidized rapidly, which leads to the fast consumption of Al and the acceleration of phase transition in the coating. Meanwhile, severe surface rumpling is observed due to the stress release of nanocrystals through plastic deformation. Besides, the reactive doping of oxygen can significantly reduce the consumption process of Al in nanocrystalline coating. The rumpling is controlled due to the improvement of coefficient of thermal expansion and Young's modulus of the coating. Thereafter, the cyclic oxidation resistance is improved.

Key words: High temperature oxidation, Thermal cycling oxidation, Surface rumpling, Nanocrystalline coating, Residual stress

Bo Meng, Jinlong Wang, Lanlan Yang, Minghui Chen, Shenglong Zhu, Fuhui Wang. On the rumpling mechanism in nanocrystalline coatings: Improved by reactive magnetron sputtering with oxygen[J]. J. Mater. Sci. Technol., 2023, 132: 69-80.

Figures/Tables 11

Table 1. EPMA-detected compositions for alloy substrate and nanocrystalline coatings (wt.%).

Elements	O	Al	Cr	Ta	W	Mo	Re	Co	Ni
Nominal N5	-	6.2	7.0	6.5	5.0	1.5	3.0	7.5	Bal.
Point 1	-	6.2	7.9	5.3	4.8	1.5	2.5	9.1	Bal.
Point 2	0.5	5.2	7.8	6.3	5.5	2.1	3.7	9.1	Bal.
Point 3	-	6.1	8.5	5.2	4.4	1.4	2.5	9.2	Bal.

Fig. 1. Typical microstructures of the as-deposited SN coating: (a) fractured morphology; (b) cross-sectional morphology by SEM; (c) the cross-sectional and (d) plan-view morphologies by TEM bright field; and (e) the corresponding SAED patterns.

Fig. 2. Typical microstructures of the as-deposited SNO coating: (a) fractured morphology; (b) cross-sectional morphology; (c) the cross-sectional and (d) plan-view morphologies by TEM bright field; and (e) the corresponding SAED patterns.

Table 2. Theoretical and experimental values for dhkl of phases of the nanocrystalline coatings.

Ring No.	d_hk_l (nm) (Fig. 1(e))	Z (_γ-Ni)	d_hk_l (nm) (Fig. 2(e))	Z (_γ-Ni)
1	0.2169	[111]	0.2135	[111]
2	0.1895	[200]	0.1893	[200]
3	0.1326	[220]	0.1315	[220]
4	0.1118	[311]	0.1123	[311]
5	-	-	0.1076	[222]
6	0.0855	[331]	0.0845	[331]

Fig. 3. (a) Oxidation kinetics of the SN and SNO coatings during cyclic oxidation test at 1100 °C; (b) XRD patterns of the coatings after cyclic oxidation at 1100 °C.

Fig. 4. Surface and cross-sectional morphologies of the oxide scales formed on the nanocrystalline coatings at 1100 °C: surface (a) and cross-sectional (b) morphologies of SN coating after 100 cycles; surface (c) and cross-sectional (d) morphologies of SNO coating after 100 cycles; surface (e) and cross-sectional (f) morphologies of SN coating after 500 cycles; surface (g) and cross-sectional (h) morphologies of SNO coating after 500 cycles.

Table 3. EDS-detected compositions for nanocrystalline coatings after 100 cycles (wt.%).

Elements		O	Al	Ta	Other
SN	1	35.0	42.4	5.4	Bal.
	2	39.9	34.8	16.4	Bal.
	3	37.1	31.8	2.3	Bal.
SNO	4	38.4	38.2	-	Bal.
SNO	5	14.3	11.7	35.1	Bal.

Fig. 5. Profile curves and 3D morphologies of the SN (a) and SNO (b) coating after cyclic oxidation at 1100 °C for different cycles.

Fig. 6. Cross-sectional microstructures of the SN (a) and SNO (b) coatings etched after 100 cycles oxidation at 1100 °C; (c) Ni-Cr-Al phase diagram [44] at 1100 °C showing the degradation of the coatings during cyclic oxidation; (d) volume fraction distribution of γ phase variation along with coating depth in (b).

Fig. 7. Elastic modulus of SN and SNO coatings before and after 100 cycles oxidation at 1100 °C.

Fig. 8. A modified version of the strain diagram, shown in Ref. [16], for the case when the bond coating is the sputtered nanocrystalline coatings. The evolution of the elastic strain in the nanocrystalline coatings compared with the traditional aluminide coatings along the path 1 → 2 → 3 → 4 → 5 → 6→7→1′ during one thermal cycle between room temperature and Tox (1100 °C).

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