J. Mater. Sci. Technol. ›› 2022, Vol. 120: 65-77.DOI: 10.1016/j.jmst.2021.10.055
• Research Article • Previous Articles Next Articles
S.M. Lia,b, L.B. Fua,b, W.L. Zhanga,b, W. Lib,*(
), J. Sunc, T.G. Wangd, S.M. Jiangb,*(), J. Gongb, C. Sunb,*()
Received:2021-07-30
Revised:2021-10-10
Accepted:2021-10-20
Published:2022-09-01
Online:2022-02-24
Contact:
W. Li,S.M. Jiang,C. Sun
About author:* E-mail addresses: wli@imr.ac.cn (W. Li),S.M. Li, L.B. Fu, W.L. Zhang, W. Li, J. Sun, T.G. Wang, S.M. Jiang, J. Gong, C. Sun. Formation process and oxidation behavior of MCrAlY + AlSiY composite coatings on a Ni-based superalloy[J]. J. Mater. Sci. Technol., 2022, 120: 65-77.
Fig. 1. Schematic drawing of detailed preparation processes for three coatings.
| Empty Cell | NiCrAlYSi target | AlSiY target |
|---|---|---|
| Arc voltage (V) | 19-21 | 19-21 |
| Arc current (A) | 80-90 | 80-90 |
| Bias voltage (-V) | 160 | 120 |
| Bias duty cycle (%) | 30 | 30 |
| Target-substrate distance(mm) | 120 | 120 |
| Air pressure (Pa) | 0.22-0.24 | 0.3 |
| Temperature (°C) | 300-400 | 300-400 |
Table 1. Deposition parameters of arc ion plating.
| Empty Cell | NiCrAlYSi target | AlSiY target |
|---|---|---|
| Arc voltage (V) | 19-21 | 19-21 |
| Arc current (A) | 80-90 | 80-90 |
| Bias voltage (-V) | 160 | 120 |
| Bias duty cycle (%) | 30 | 30 |
| Target-substrate distance(mm) | 120 | 120 |
| Air pressure (Pa) | 0.22-0.24 | 0.3 |
| Temperature (°C) | 300-400 | 300-400 |
Fig. 2. Cross-sectional morphologies of C1 during annealing process, (a) as-deposited, (b) heated to 700 °C, (c) heated to 900 °C, (d) heated to 1000 °C and held for 30 min, (e) at the ending of annealing, (f-h) bright-field images of precipitates in the outermost layer of annealed C1.
| Location | Average composition | ||||||
|---|---|---|---|---|---|---|---|
| Al | Si | Cr | Co | Ni | W | Ti | |
| zone 1 in the C1 | 45.4 | 1 | 5.2 | 5.4 | 38.1 | 3.4 | 1.5 |
| zone 2 in the C1 | 40 | 1 | 6.4 | 6.4 | 39.1 | 5.4 | 1.7 |
| zone 3 in the C1 | 34.1 | 2.1 | 6.4 | 7.3 | 40.4 | 8.6 | 2.1 |
| zone 4 in the C1 | 24.1 | 1.3 | 6.4 | 8.4 | 50.7 | 8.1 | 1 |
| zone 5 in the C1 | 24.1 | 1.7 | 7.8 | 8 | 49.3 | 7.6 | 1.4 |
| zone 6 in the C1 | 23.4 | — | 4.5 | 9.3 | 60 | 2.8 | — |
| zone 1 in the C2 | 43.5 | 2.1 | 14 | — | 40.4 | — | — |
| zone 2 in the C2 | 33.3 | 3.4 | 17 | — | 46.3 | — | — |
| zone 3 in the C2 | 39.6 | 0.6 | 13.4 | — | 46.4 | — | — |
| zone 4 in the C2 | 35.4 | 0.4 | 15.7 | — | 48.5 | — | — |
| zone 7 in the C2 | 24.8 | 3 | 16.4 | — | 55.8 | — | — |
| zone 8 in the C2 | 25.4 | 0.3 | 11.8 | 0.7 | 61.8 | — | — |
| zone 10 in the C2 | 23.7 | 3 | 16.3 | 0.7 | 56.3 | — | — |
| zone 11 in the C2 | 15 | — | 29.9 | 4.6 | 48.3 | 2.3 | — |
| zone 5 in the C3 | 21.8 | 1.8 | 14 | 0.4 | 62 | — | — |
| zone 6 in the C3 | 13.6 | — | 32.1 | 2.6 | 49.6 | 2.1 | — |
Table 2. The average compositions of coatings (wt.%).
| Location | Average composition | ||||||
|---|---|---|---|---|---|---|---|
| Al | Si | Cr | Co | Ni | W | Ti | |
| zone 1 in the C1 | 45.4 | 1 | 5.2 | 5.4 | 38.1 | 3.4 | 1.5 |
| zone 2 in the C1 | 40 | 1 | 6.4 | 6.4 | 39.1 | 5.4 | 1.7 |
| zone 3 in the C1 | 34.1 | 2.1 | 6.4 | 7.3 | 40.4 | 8.6 | 2.1 |
| zone 4 in the C1 | 24.1 | 1.3 | 6.4 | 8.4 | 50.7 | 8.1 | 1 |
| zone 5 in the C1 | 24.1 | 1.7 | 7.8 | 8 | 49.3 | 7.6 | 1.4 |
| zone 6 in the C1 | 23.4 | — | 4.5 | 9.3 | 60 | 2.8 | — |
| zone 1 in the C2 | 43.5 | 2.1 | 14 | — | 40.4 | — | — |
| zone 2 in the C2 | 33.3 | 3.4 | 17 | — | 46.3 | — | — |
| zone 3 in the C2 | 39.6 | 0.6 | 13.4 | — | 46.4 | — | — |
| zone 4 in the C2 | 35.4 | 0.4 | 15.7 | — | 48.5 | — | — |
| zone 7 in the C2 | 24.8 | 3 | 16.4 | — | 55.8 | — | — |
| zone 8 in the C2 | 25.4 | 0.3 | 11.8 | 0.7 | 61.8 | — | — |
| zone 10 in the C2 | 23.7 | 3 | 16.3 | 0.7 | 56.3 | — | — |
| zone 11 in the C2 | 15 | — | 29.9 | 4.6 | 48.3 | 2.3 | — |
| zone 5 in the C3 | 21.8 | 1.8 | 14 | 0.4 | 62 | — | — |
| zone 6 in the C3 | 13.6 | — | 32.1 | 2.6 | 49.6 | 2.1 | — |
Fig. 3. XRD patterns for C1 during annealing process.
Fig. 4. Cross-sectional morphologies of C2 during annealing process, (a) as-deposited, (b) heated to 700 °C, (c) heated to 900 °C, (d) heated to 1000 °C and held for 30 min, (e) at the ending of annealing, (f, g) bright-field images of annealed C2.
Fig. 5. XRD patterns for C2 during annealing process.
Fig. 6. Cross-sectional morphologies of C3 during annealing process, (a) as-deposited, (b) heated to 700 °C, (c) heated to 900 °C, (d) heated to 1000 °C and held for 30 min, (e) at the ending of annealing.
Fig. 7. XRD patterns for C3 during annealing process.
Fig. 8. Isothermal oxidation kinetic curves for coatings at 1100 °C, (a) total mass change, (b) square of mass gain versus oxidation time of coating, which displayed the oxidation rate constant (kp).
Fig. 9. XRD patterns of coatings after 50 and 200 h isothermal oxidation at 1100 °C, (a) C1, (b) C2 and (c) C3.
Fig. 10. Cross-sectional images of coatings after isothermal oxidation at 1100 °C, (a, d) C1, (b, e) C2, (c, f) C3, (a-c) for 50 h, (d-f) for 300 h.
Fig. 11. Surface images of coatings after isothermal oxidation at 1100 °C, (a, d) C1, (b, e) C2, (c, f) C3, (a-c) for 50 h, (d-f) for 300 h.
Fig. 12. Raman spectrogram of Al2O3 scale formed on the coating.
Fig. 13. Schematic drawing of coatings formation in vacuum annealing process.
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