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Acta Metall Sin  2017, Vol. 53 Issue (12): 1636-1644    DOI: 10.11900/0412.1961.2017.00192
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Comparative Study of Thermal Shock Behavior of the Arc Ion Plating NiCrAlY and the Enamel Based Composite Coatings
Min FENG1, Minghui CHEN2(), Zhongdi YU2, Zhenbo LV1, Shenglong ZHU3, Fuhui WANG2
1 Devision of Chemistry, Chemical Engineering and Environment, Liaoning Shihua University, Fushun 113001, China
2 Key Laboratory for Anisotropy and Texture of Materials (Ministry of Education), School of Materials Science and Engineering, Northeastern University, Shenyang 110819, China
3 Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China;
Cite this article: 

Min FENG, Minghui CHEN, Zhongdi YU, Zhenbo LV, Shenglong ZHU, Fuhui WANG. Comparative Study of Thermal Shock Behavior of the Arc Ion Plating NiCrAlY and the Enamel Based Composite Coatings. Acta Metall Sin, 2017, 53(12): 1636-1644.

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Abstract  

From the view of material point, high-temperature protective coatings are divided into the following two categories: ceramic coating and metallic coating. Metallic coating possesses higher toughness and bond strength to the alloy substrate than ceramic coating does. Its protectiveness relies on the formation of a slow-growing and adherent oxide scale at high temperatures. However, with increasing the oxidation time, the oxide scale will experience cracking and spalling as it has grown to the critical thickness. Ceramic coating due to its chemical inertness has been used in many corrosive environments for protection. But the weak interfacial bond and big mismatch of coefficient of thermal expansion with the alloy substrate limit its application in thermal shock environments. Since glass-ceramics combine the generally superior properties of crystallite ceramics with the easy processing of glasses, it is expected that glass-ceramic coating should show a higher spallation resistance than ceramic one under thermal shock. Cast K444 superalloy is widely used in advanced aircraft engine and gas turbine. Its protection from high-temperature oxidation under thermal shock becomes a critic issue. In this work, NiCrAlY and enamel based composite coatings on the K444 superalloy substrate by arc ion plating and spray-firing methods were prepared, respectively. Thermal shock behavior from 900 ℃ to room temperature of these two coatings was studied comparatively. One cycle of thermal shock contained the holding of samples at 900 ℃ for 1.5 h and the following cooling down in air or water. Results indicated that thermal shock resistance of the NiCrAlY coating was low. As the NiCrAlY coating was thermal shocked by water, its oxide scale cracked severely after 30 cyc, and certain crack had already transported the scale and penetrated into the interior of the underlying metallic coating; for the enamel based composite coating, however, its thermal shock resistance was high. No cracks were detected at the coating surface or interior after thermal shock test. Besides, the enamel coating still adhered well with the alloy substrate. The high resistance to thermal shock of the enamel based composite coating originated from: (1) the coefficient of thermal expansion of the enamel based composite coating matched well with that of the alloy substrate; (2) the addition of nano-sized Ni and NiCrAlY metallic particles improved the toughness of the enamel coating, in addition to enhancing its coefficient of thermal expansion.

Key words:  NiCrAlY coating      enamel coating      thermal shock      superalloy     
Received:  22 May 2017     
ZTFLH:  TG174.4  
Fund: Supported by National Natural Science Foundation of China (No.51471177) and Fundamental Research Funds for the Central Universities (No.N160205001)

URL: 

https://www.ams.org.cn/EN/10.11900/0412.1961.2017.00192     OR     https://www.ams.org.cn/EN/Y2017/V53/I12/1636

Fig.1  Thermal shock kinetics of K444 superalloy, NiCrAlY coating and the enamel based composite coating from 900 ℃ to room temperature in water (W) or in air (A)
Fig.2  XRD spectra of K444 superalloy (a), NiCrAlY coatings (b) and enamel composite coating (c) before (as fired) and after thermal shock in water or in air for 30 cyc
Fig.3  Surface (a, c) and cross-sectional (b, d) microstructures of K444 superalloy after thermal shock in air (a, b) and in water (c, d) for 30 cyc
Fig.4  Surface (a, c) and cross-sectional (b, d) microstructures of NiCrAlY coating after thermal shock in air (a, b) and in water (c, d) for 30 cyc
Fig.5  Surface (a, c, e) and cross-sectional (b, d, f) microstructures of enamel composite coatings before (as-fired) (a, b) and after thermal shock in air (c, d) and in water (e, f) for 30 cyc (Inset in Fig.5e shows the local enlarged image, and inset in Fig.5f shows the corresponding line scan result)
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