Effect of High-Current Pulsed Electron Beam Irradiation on Microstructure and Properties of MCrAlY Coating Prepared by Low-Pressure Plasma Spraying
CAI Jie1,2(), GAO Jie1,2, HUA Yinqun2, YE Yunxia2, GUAN Qingfeng3, ZHANG Xiaofeng4
1 Institute of Advanced Manufacturing and Modern Equipment Technology, Jiangsu University, Zhenjiang 212013, China 2 School of Mechanical Engineering, Jiangsu University, Zhenjiang 212013, China 3 School of Materials Science and Engineering, Jiangsu University, Zhenjiang 212013, China 4 Institute of New Materials, Guangdong Academy of Science, Guangzhou 510650, China
Cite this article:
CAI Jie, GAO Jie, HUA Yinqun, YE Yunxia, GUAN Qingfeng, ZHANG Xiaofeng. Effect of High-Current Pulsed Electron Beam Irradiation on Microstructure and Properties of MCrAlY Coating Prepared by Low-Pressure Plasma Spraying. Acta Metall Sin, 2024, 60(4): 495-508.
MCrAlY-type coatings are widely applied to thermally loaded structures of aero-engines as standalone overlays and as a bond-coat for a thermal barrier coating system, owing to their good resistance to high-temperature oxidation and hot corrosion. The thermally grown oxide (TGO) formed at the interface is the primary factor affecting the durability of MCrAlY coatings, which is closely related to the coating method used. The coating performed by low-pressure plasma spraying (LPPS) has great adhesion, high deposition rate, and low internal oxidation. However, the prepared defects of rough surface and porosity adversely affect the antioxidant performance. High-current pulsed electron beam (HCPEB), as a powerful tool for surface modification of different materials, can normalize the defects, polish the coating surface, and reconstruct microstructures, which is crucial to promote steady growth of the protective TGO. Therefore, in this work, NiCrAlY coatings were prepared on the surface of a nickel-based superalloy via LPPS and then irradiated via HCPEB. The microstructural evolution, static oxidation performance at 1150oC, and TGO residual stress distribution of NiCrAlY coatings before and after HCPEB modification were compared. The microstructural results show that the surface of the as-sprayed coating was rather rough and there were many unmelted large particles. After HCPEB irradiation, the surface of the irradiated coating was remelted, and became much flat and smooth. A rather dense and compact remelted layer approximately 12 μm in thickness was obtained. Furthermore, deformation structures and Y-Al enriched nanodispersed particles were introduced inside the remelted layer. The results of static oxidation and TGO residual stress show that after 150 h of oxidation, the oxide film formed on the as-sprayed coating fell off locally, accompanied by serious internal oxidation. Due to the cracking and peeling of the TGO, the internal stress was released. Conversely, the oxide film on the remelted surface of HCPEB irradiated coating grew steadily, and there was no trace of peeling, and the TGO stress increased steadily. The experimental results show that HCPEB is an effective and promising approach to drastically improve the high-temperature oxidation resistance of thermally sprayed MCrAlY coatings.
Fund: National Natural Science Foundation of China(U1933124);China Postdoctoral Science Foundation(2021M701476);Postgraduate Research & Practice Innovation Program of Jiangsu Province(SJCX21_1699)
Corresponding Authors:
CAI Jie, associate professor, Tel: (0511)88797906, E-mail: caijie@ujs.edu.cn
Fig.1 XRD spectra of NiCrAlY coatings before and after high-current pulsed electron beam (HCPEB) modification
Fig.2 Morphologies and EDS analyses of NiCrAlY coatings before and after HCPEB modification (a) three-dimensional graph of the as-sprayed coating (Sa—surface roughness) (b, c) surface (b) and cross-section (c) morphologies of the as-sprayed coating (d) three-dimensional graph of the irradiated coating (e, f) surface (e) and cross-section (f) morphologies of the irradiated coating (g) EDS mapping of the irradiated coating
Region
O
Al
Cr
Ni
Y
A
2.87
22.55
19.33
53.91
1.34
B
5.45
13.83
40.98
38.62
1.12
Table 2 EDS results of each region in Fig.2f
Fig.3 TEM images and EDS analyses of NiCrAlY coatings before and after HCPEB modification (a) as-sprayed coating (b) bright field image of region A in Fig.3a (c) dark field image of region A in Fig.3a and corresponding EDS mappings (d) irradiated coating (e) bright field image of region B in Fig.3d (f) dark field image of region B in Fig.3d and corresponding EDS mappings
Fig.4 Al2O3 Raman peak spectra of NiCrAlY coatings before (a-c) and after (d-f) HCPEB modification at 1150oC in transient oxidation for 5 min (a, d), 15 min (b, e), and 30 min (c, f)
Fig.5 Transient oxidation morphologies of NiCrAlY coatings before (a-c) and after (d-f) HCPEB modification at 1150oC for 5 min (a, d), 15 min (b, e), and 30 min (c, f) (Inset in Fig.5d shows morphology of θ -Al2O3)
Region
O
Al
Cr
Ni
Y
A
47.44
37.41
5.55
9.50
0.10
B
58.05
34.41
3.57
3.97
-
C
47.97
38.17
4.54
9.32
-
D
49.97
39.43
4.50
6.10
-
E
45.36
31.08
6.27
17.29
-
F
48.03
39.54
4.79
7.64
-
G
42.26
43.90
4.94
8.39
0.51
H
55.13
38.07
2.72
3.97
0.11
I
49.42
41.01
4.32
5.14
0.11
J
49.76
40.23
2.94
7.07
-
Table 3 EDS results of each region in Fig.5
Fig.6 XRD spectra of NiCrAlY coatings after long-term oxidation at 1150oC for different time before (a) and after (b) HCPEB modification
Fig.7 Cross-section morphologies and EDS analyses of the as-sprayed coating after long-term oxidation at 1150oC for 10 h (a), 50 h (b), 100 h (c), and 150 h (d) (δTGO—average thickness of the thermally grown oxide (TGO))
Fig.8 Cross-section morphologies and EDS analyses of the irradiated coating after long-term oxidation at 1150oC for 10 h (a), 50 h (b), 100 h (c), and 150 h (d)
Fig.9 Curves of TGO residual stress versus oxidation time (t)
Fig.10 TGO growth kinetics (a) and fitting lines (b) of NiCrAlY coatings before and after HCPEB modification (Kp—growth rate of oxide film)
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