Preparation and Enhanced Hot Corrosion Resistance of aZr-Doped PtAl2+(Ni, Pt)Al Dual-Phase Coating

doi:10.11900/0412.1961.2017.00376

Acta Metall Sin

2018, Vol. 54

Issue (4): 581-590 DOI: 10.11900/0412.1961.2017.00376

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Preparation and Enhanced Hot Corrosion Resistance of aZr-Doped PtAl₂+(Ni, Pt)Al Dual-Phase Coating

Chengyang JIANG^1,², Yingfei YANG², Zhengyi ZHANG³, Zebin BAO²(

), Shenglong ZHU², Fuhui WANG¹

1 School of Materials Science and Engineering, Northeastern University, Shenyang 110819, China
2 Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
3 China National South Aviation Industry Co., Ltd., Zhuzhou 412002, China

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Chengyang JIANG, Yingfei YANG, Zhengyi ZHANG, Zebin BAO, Shenglong ZHU, Fuhui WANG. Preparation and Enhanced Hot Corrosion Resistance of aZr-Doped PtAl₂+(Ni, Pt)Al Dual-Phase Coating. Acta Metall Sin, 2018, 54(4): 581-590.

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Abstract

Prior to practical service, hot-section components (e.g. airfoils and vanes) of a gas turbine engine are necessarily coated by a protective metallic coating (such as aluminide diffusion coating, modified aluminide coating and MCrAlY overlay etc.) to resist high temperature oxidation and hot corrosion. Among the modified aluminide coatings, the coating with Pt-modification has attracted great attention and is widely used in applications requiring high reliability and extended service life since it possesses superior oxidation/corrosion resistance at high temperature. The presence of Pt in aluminide coating is favorable for increasing bonding strength of oxide scale, enlarging phase region of β-NiAl and confining detrimental effect of sulphur etc. Although Pt-modification has exhibited visible benefits for acquiring better high-temperature performance, it is far from satisfaction to develop an ideal aluminide diffusion coating. Reactive elements such as Y, Hf, Zr or their oxides have been employed to modify the nickel aluminide coating system, with an aim to further improve scale adhesion and promote exclusive formation of α-Al₂O₃simultaneously. In this work, a Zr-doped PtAl₂+(Ni, Pt)Al dual-phase aluminide coating was prepared on a Ni-based single crystal superalloy by co-deposition of Pt-Zr through electroplating and subsequent aluminization treatments. The coating was mainly composed of three layers: the outmost layer consisted of double phases with PtAl₂ particles dispersed in β-(Ni, Pt)Al domain, while the interlayer comprised β-(Ni, Pt)Al with small amount of Cr-precipitates, and the bottom layer was an inter-diffusion zone (IDZ). Zirconium was mainly distributed inside β-(Ni, Pt)Al solid solution in both the outmost layer and the interlayer. Compared with normal PtAl₂+(Ni, Pt)Al dual-phase coating, the hot corrosion behavior of the Zr-doped PtAl₂+(Ni, Pt)Al coating was assessed in a salt mixture of Na₂SO₄/NaCl (75:25, mass ratio) at 850 ℃ in static air. The results indicated that the Zr-doped PtAl₂+(Ni, Pt)Al dual-phase coating exhibited superior hot corrosion resistance since Zr was confirmed able to capture and fix S and Cl to diminish their detrimental effects. Meanwhile, a pre-oxidation treatment did not effectively improve the overall hot corrosion resistance of normal PtAl₂+(Ni, Pt)Al coating because the thin alumina scale formed during pre-oxidation was unable to prohibit the sustained inward-invasion of the mixed salt.

Key words: Zr-doping reactive element Pt-Al coating hot corrosion

Received: 08 September 2017

ZTFLH:

TG174.44

Fund: Supported by National Natural Science Foundation of China (Nos.51671202 and 51301184), Defense Industrial Technology Development Program (No.JCKY2016404C001) and Liaoning BaiQianWan Talents Program

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	Chengyang JIANG
	Yingfei YANG
	Zhengyi ZHANG
	Zebin BAO
	Shenglong ZHU
	Fuhui WANG

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https://www.ams.org.cn/EN/10.11900/0412.1961.2017.00376 OR https://www.ams.org.cn/EN/Y2018/V54/I4/581

Fig.1 Surface (a) and cross-sectional (b) SEM images of the Pt-Zr composite plating on N5 substrate

Fig.2 Cross-sectional SEM images of the normal (a) and Zr-doped (b) PtAl₂+(Ni, Pt)Al dual-phase coatings (IDZ—iner-diffusion zone)

Fig.3 XRD spectra of the normal and Zr-doped PtAl₂+(Ni, Pt)Al dual-phase coatings

Fig.4 Mass change curves of N5 substrate, pre-oxidized, normal and Zr-doped PtAl₂+(Ni, Pt)Al dual-phase coatings corroded in Na₂SO₄/NaCl (75:25, mass ratio) mixed salt at 850 ℃

Fig.5 XRD spectra of the normal and Zr-doped PtAl₂+(Ni, Pt)Al dual-phase coating specimens corroded in Na₂SO₄/NaCl mixed salt at 850 ℃ for 60 h

Fig.6 Cross-sectional SEM images of the normal (a) and Zr-doped (b) PtAl₂+(Ni, Pt)Al dual-phase coating specimens corroded in Na₂SO₄/NaCl mixed salt at 850 ℃ for 60 h

Fig.7 XRD spectra of the normal and Zr-doped PtAl₂+(Ni, Pt)Al dual-phase coating specimens corroded in Na₂SO₄/NaCl mixed salt at 850 ℃ for 100 h

Fig.8 Cross-sectional SEM images of the normal (a) and Zr-doped (b) PtAl₂+(Ni, Pt)Al dual-phase coating specimens corroded in Na₂SO₄/NaCl mixed salt at 850 ℃ for 100 h

Fig.9 Elemental mapping for the normal PtAl₂+(Ni, Pt)Al dual-phase coating specimen corroded in Na₂SO₄/NaCl mixed salt at 850 ℃ for 100 h

Fig.10 Elemental mapping for the Zr-doped PtAl₂+(Ni, Pt)Al dual-phase coating specimen corroded in Na₂SO₄/NaCl mixed salt at 850 ℃ for 100 h

Fig.11 Cross-sectional SEM image of the normal PtAl₂+(Ni, Pt)Al dual-phase coating after pre-oxidation treatment for 4 h

Fig.12 XRD spectra of the normal PtAl₂+(Ni, Pt)Al dual-phase coating after pre-oxidation and successive hot corrosion test in Na₂SO₄/NaCl mixed salt for 100 h

Fig.13 Cross-sectional SEM image of the normal PtAl₂+(Ni, Pt)Al dual-phase coating after pre-oxidation and hot corrosion in Na₂SO₄/NaCl mixed salt at 850 ℃ for 100 h

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