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Acta Metall Sin  2026, Vol. 62 Issue (6): 1069-1081    DOI: 10.11900/0412.1961.2025.00127
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Microstructure and High-Temperature Oxidation Behavior of Silicide-Boride Composite Coatings on the Surface of Mo
WU Zhou1, WU Fan2, WANG Yiming1, GAN Youliang1, FU Xuesong1, CHEN Guoqing1, ZHOU Wenlong1, ZU Yufei1()
1 School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024, China
2 AVIC Manufacturing Technology Institute, Beijing 100024, China
Cite this article: 

WU Zhou, WU Fan, WANG Yiming, GAN Youliang, FU Xuesong, CHEN Guoqing, ZHOU Wenlong, ZU Yufei. Microstructure and High-Temperature Oxidation Behavior of Silicide-Boride Composite Coatings on the Surface of Mo. Acta Metall Sin, 2026, 62(6): 1069-1081.

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Abstract  

Mo and its alloys exhibit considerable potential for aerospace high-temperature components, electronic thermal management systems, and high-temperature power-generation structures due to their high melting point, excellent elevated-temperature mechanical strength, and good creep resistance. However, their application is severely limited by rapid oxidation at temperatures above 700 oC, where the formation and volatilization of MoO3 lead to accelerated material loss and structural degradation. This oxidation susceptibility can ultimately result in disintegration and catastrophic failure under extreme service conditions. The application of silicide-based coatings is an effective strategy to mitigate high-temperature oxidation by forming a protective barrier that isolates the substrate from the environment. Nevertheless, monolithic silicide coatings often suffer from premature failure caused by thermal expansion mismatch with the substrate and inward silicon diffusion during prolonged high-temperature exposure. In this context, silicide-boride composite coatings have emerged as a promising alternative for further improving oxidation resistance. Despite their potential, the mechanisms governing gradient microstructure formation and the origins of performance variability in such composite coatings remain insufficiently understood. In this study, silicide and silicide-boride composite coatings were fabricated on pure Mo substrates using halide-activated pack cementation, and their microstructural evolution and high-temperature oxidation behavior were systematically investigated. The results demonstrate that B element incorporation promotes the formation of a silicide-boride composite coating with a five-layer graded structure: MoSi2/(MoSi2 + MoB)/Mo5Si3/MoB/Mo2B. Notably, B facilitates the preferential formation of an initial MoB interlayer at the coating-substrate interface. This interlayer not only inhibits the directional diffusion of Si but also induces a displacement reaction between Si and MoB to form MoSi2, thereby suppressing the (001) preferred growth orientation of MoSi2. In addition, volume contraction associated with MoB formation within the MoSi2 + MoB mixed layer generates pores and a roughened interface, which act as high-density nucleation sites and significantly refine the surface MoSi2 grain structure. The refined grain structure accelerated the formation of a dense and continuous SiO2 protective film, thereby effectively inhibiting O diffusion. After 30 h of oxidation at 1200 oC, the silicide-boride composite coating exhibited an oxidation mass gain of 1.28 mg/cm2 and an oxidation rate constant of 0.29 mg/(cm2·h), representing a 53% reduction relative to the silicide coating. Moreover, the MoB interlayer suppressed inward Si diffusion into the substrate, thereby enhancing long-term stability under high-temperature oxidative conditions.

Key words:  silicide-boride composite coating      halide-activated pack cementation      high-temperature oxidation      Mo     
Received:  08 May 2025     
ZTFLH:  TG174.4  
Fund: National Natural Science Foundation of China(51805069)
Corresponding Authors:  ZU Yufei, associate professor, Tel: 13704112760, E-mail: yfzu@dlut.edu.cn

URL: 

https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00127     OR     https://www.ams.org.cn/EN/Y2026/V62/I6/1069

Fig.1  XRD patterns of the surfaces of silicide coating and silicide-boride composite coating
Fig.2  Surface SEM images of the silicide coating (a) and silicide-boride composite coating (b) (Insets in Figs.2a and b show the corresponding grain size distributions); EDS analyses of spot 1 (c) and spot 2 (d) in Fig.2b
Fig.3  Low (a, c) and locally high (b, d) magnified cross-sectional SEM images of the silicide coating (a, b) and silicide-boride composite coating (c, d)
CoatingLayerSpotAtomic fraction / %Possible phase
BSiMo
Silicide coatingLayer I1-65.8034.20MoSi2
Layer II2-37.6462.36Mo5Si3
Silicide-boride composite coatingLayer I3-64.2135.79MoSi2
Layer II451.440.5548.01MoB
5-67.0532.95MoSi2
Layer III60.7636.3862.86Mo5Si3
Layer IV759.25-40.75MoB
Layer V830.95-69.05Mo2B
Table 1  Chemical compositions of the spots 1-8 in Fig.3 determined by EDS
Fig.4  Cross-sectional EBSD analysis results of the silicide coating (a, b) and silicide-boride composite coating (c-e) (a, b) phase distribution map (a) and inverse pole figure (IPF) of MoSi2 along GD (b) of silicide coating (GD—growth direction, RD—rolling direction, ND—normal direction) (c-e) phase distribution map (c) and IPFs of MoSi2 (d) and MoB (e) along GD of silicide-boride composite coating
Fig.5  Cross-sectional pole figures (PFs) of different phases in the silicide coating (a) and silicide-boride composite coating (b-d)
(a) PF of MoSi2 in silicide coating
(b) PF of MoSi2 in silicide-boride composite coating
(c, d) PFs of MoB in the MoB layer (c) and MoSi2 + MoB layer (d) of silicide-boride composite coating
Fig.6  XRD patterns on the surfaces of silicide-boride composite coating at different holding time
Fig.7  Cross-sectional SEM images of silicide-boride composite coating at holding time of 0 h (a-c), 1.5 h (d), 3 h (e), and 10 h (f) (Inset in Fig.7a shows the locally enlarged image of the rectangle zone)
Fig.8  Growth kinetics curves of silicide-boride composite coating prepared at 1200 oC (t—holding time, R2—coefficient of determination)
Fig.9  Equilibrium partial pressures (P) of the main gas phases for 30Si-5NaCl-65Al2O3 (a) and 30Si-1B-5NaCl-64Al2O3 (b) infiltrant powders under different temperatures
Fig.10  Schematics of the formation mechanisms of silicide coating (a) and silicide-boride composite coating (b) on the surface of pure Mo (JSi, JMo, and JB represent the diffusion fluxes of Si, Mo, and B atoms, respectively)
Fig.11  Oxidation kinetics curves of silicide coating and silicide-boride composite coating at 1200 oC
Fig.12  XRD patterns of silicide coating (a) and silicide-boride composite coating (b) after oxidation at 1200 oC for 1 and 30 h
Fig.13  Surface SEM images of silicide coating (a, c) and silicide-boride composite coating (b, d) after oxidation at 1200 oC for 1 h (a, b) and 30 h (c, d) (Circles in Fig.13c indicate pores)
SpotAtomic fraction / %Possible phase
OAlSiMo
13.12-62.7334.15MoSi2
267.720.6030.770.91SiO2
354.685.7339.59-SiO2, Al2O3
43.42-63.1333.45MoSi2
547.439.6033.249.73SiO2, Al2O3, MO3
655.486.1736.851.50SiO2, Al2O3
750.6013.6220.5215.26SiO2, Al2O3, MO3
843.3910.7735.6610.18SiO2, Al2O3, MO3
954.9610.1434.90-SiO2, Al2O3
Table 2  Chemical compositions of the spots 1-9 in Fig.13 determined by EDS
Fig.14  Low (a, b) and locally high (c, d) magnified cross-sectional SEM images of silicide coating (a, c) and silicide-boride composite coating (b, d) after oxidation at 1200 oC for 1 h (Insets in Figs.14a and b show locally enlarged images of rectangle zones. Arrows in Figs.14c and d indicate the diffusion paths of Si element)
SpotAtomic fraction / %Possible
BOSiMophase
1-4.5034.5960.91Mo5Si3
2-4.9034.3260.78Mo5Si3
3--35.7364.27Mo5Si3
4--34.4365.57Mo5Si3
550.11-0.2949.60MoB
638.27-0.3161.42Mo2B
Table 3  Chemical compositions of the spots 1-6 in Fig.14 determined by EDS
Fig.15  Low (a, b) and locally high (c, d) magnified cross-sectional SEM images of silicide coating (a, c) and silicide-boride composite coating (b, d) after oxidation at 1200 oC for 30 h (Arrow in Fig.15b indicate the diffusion path of Si element)
SpotAtomic fraction / %Possible phase
OAlSiMo
126.087.5666.36-SiO2, Al2O3
23.98-34.0961.93Mo5Si3
32.20-64.8033.00MoSi2
457.585.8134.761.85SiO2, Al2O3
55.92-34.5259.56Mo5Si3
62.25-64.7433.01MoSi2
Table 4  Chemical compositions of the spots 1-6 in Fig.15 determined by EDS
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