Preparation and Performance of a Novel Wear-Resistant and High Temperature Oxidation-Resistant NiCrAlSiC Composite Coating

doi:10.11900/0412.1961.2019.00034

Acta Metall Sin

2019, Vol. 55

Issue (7): 902-910 DOI: 10.11900/0412.1961.2019.00034

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Preparation and Performance of a Novel Wear-Resistant and High Temperature Oxidation-Resistant NiCrAlSiC Composite Coating

Mingyu ZHAO¹,Huijuan ZHEN^2,³(

),Zhihong DONG²,Xiuying YANG¹(

),Xiao PENG⁴

1. Shenyang Institute of Technology, Fushun 113122, China
2. Laboratory for Corrosion and Protection, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
3. School of Materials Science and Engineering, University of Science and Technology of China, Shenyang 110016, China
4. School of Materials Science and Engineering, Nanchang Hangkong University, Nanchang 330063, China

Cite this article:

Mingyu ZHAO,Huijuan ZHEN,Zhihong DONG,Xiuying YANG,Xiao PENG. Preparation and Performance of a Novel Wear-Resistant and High Temperature Oxidation-Resistant NiCrAlSiC Composite Coating. Acta Metall Sin, 2019, 55(7): 902-910.

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Abstract

MCrAl (M=Ni, Co, or their combinations) coatings have been widely used as high temperature oxidation protection coatings on turbine blades, as they can thermally grow stable, dense and well adherent Al₂O₃ protective scales. Due to the particulate nature of the exhaust, MCrAl coatings often fail owing to severe high-temperature wear. To improve the anti-wear resistance of the MCrAl coatings, NiCrAlSiC composite coatings were designed and fabricated by the combination of electrophoretic deposition (EPD) and electrodeposition (ED). The compositions, morphologies and structures of the as-deposited composite coatings were characterized by XRD, SEM, EPMA and TEM. A Ni7.4Cr6.2Al14.3SiC (mass fraction, %) coating, as well as a contrast SiC-free Ni7.2Cr6.2Al coating, was prepared. No cracks or micro pores were found either at the coating/substrate interface or in the coating, and elements distributed uniformly in the coating. Compared to the SiC-free coating, oxide scale on the NiCrAlSiC coating transformed from a three-layered structure (NiO, NiAl₂O₄ and Al₂O₃) to a thinner two-layered structure (NiAl₂O₄ and Al₂O₃), showing better high temperature oxidation resistance. And microhardness of the NiCrAlSiC coating increased 26%, together with the wear rate reduced 52%. Wear mechanism of the NiCrAl coating was abrasive wear, while that of the NiCrAlSiC coating switched to adhesive wear. These results indicate that the addition of SiC improves both high temperature oxidation resistance and wear resistance of the NiCrAl composite coating obviously.

Key words: NiCrAl composite coating high temperature oxidation friction and wear electrophoretic deposition electrodeposition

Received: 02 February 2019

ZTFLH:

TG174.4

Fund: Natural Science Foundation of Liaoning Province(No.20170540666)

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	Mingyu ZHAO
	Huijuan ZHEN
	Zhihong DONG
	Xiuying YANG
	Xiao PENG

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https://www.ams.org.cn/EN/10.11900/0412.1961.2019.00034 OR https://www.ams.org.cn/EN/Y2019/V55/I7/902

Fig.1 Schematics of preparation of the NiCrAlSiC composite coating by the combination of electrophoretic deposition (EPD) and electrodeposition (ED)(a) EPD of CrAl and SiC particles and forming a porous CrAlSiC coating (b) ED of Ni into the space among the particles thus obtaining dense and adherent NiCrAlSiC coating

Fig.2 XRD spectra of EPD+ED deposited NiCrAl and NiCrAlSiC composite coatings

Fig.3 Low (a, b) and high (c, d) magnified surface morphologies of EPD+ED deposited NiCrAl (a, c) and NiCrAlSiC (b, d) coatings

Fig.4 Low (a, b) and high (c, d) magnified longitudinal-sectional morphologies of EPD+ED deposited NiCrAl (a, c) and NiCrAlSiC (b, d) coatings

Fig.5 Backscattered electron image (BEI) and EPMA element maps of an as-deposited NiCrAlSiC composite coating

Fig.6 Bright field TEM image of the as-deposited NiCrAl coating close to the NiCrAl/Ni substrate interface

Fig.7 Low (a, b) and high (c, d) magnified surface morphologies of oxide scales on the NiCrAl (a, c) and NiCrAlSiC (b, d) coatings oxidized in air at 900 ℃ for 20 h

Fig.8 Low (a, b) and high (c, d) magnified cross-sectional morphologies of oxide scales on the NiCrAl (a, c) and NiCrAlSiC (b, d) coatings oxidized in air at 900 ℃ for 20 h

Table 1 Compositions of oxide films on the NiCrAl and NiCrAlSiC coatings in Fig.8

Fig.9 The friction coefficient vs time curves of NiCrAl and NiCrAlSiC coatings

Fig.10 Low (a, c) and high (b, d) magnified worn surface morphologies of the NiCrAl (a, b) and NiCrAlSiC (c, d) composite coatings after wear test

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