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Acta Metall Sin  2014, Vol. 50 Issue (10): 1170-1178    DOI: 10.11900/0412.1961.2014.00077
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ISOTHERMAL OXIDATION BEHAVIOR OF Al-Cr COATING ON Ni-BASED SUPERALLOY
WU Duoli, JIANG Sumeng(), FAN Qixiang, GONG Jun, SUN Chao
Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016
Cite this article: 

WU Duoli, JIANG Sumeng, FAN Qixiang, GONG Jun, SUN Chao. ISOTHERMAL OXIDATION BEHAVIOR OF Al-Cr COATING ON Ni-BASED SUPERALLOY. Acta Metall Sin, 2014, 50(10): 1170-1178.

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Abstract  

Currently, Ni-based superalloys are widely applied to turbine blades or other components of gas turbines for their excellent high temperature mechanical properties. These components must exhibit a high level of resistance to the oxidation and corrosion conditions generated by the combustion environment. The general design philosophy is to select a high strength substrate alloy to withstand the stress and apply a surface coating to give maximum protection from the environment. In this work, a Cr-modified aluminide (Al-Cr) coating were prepared by combining arc ion plating and pack cementation aluminizing. As a contrast, a simple aluminide coating was developed by pack cementation aluminizing. The isothermal oxidation behaviors at 1000 and 1100 ℃ were investigated on the Ni-based superalloy DSM11 substrate, aluminide coating and Al-Cr coating. The results demonstrate that aluminide coating and Al-Cr coating are dense and adhere tightly to the substrate. The microstructures of aluminized coating and Al-Cr coating are divided in two distinguished areas: the outer layer and the interdiffusion zone. The outer layer of the aluminized coating is composed of b-NiAl and Ni2Al3 phases, while the Al-Cr coating consists of b-NiAl, Ni2Al3, a-Cr and AlCr2 phases. The DSM11 substrate shows bad oxidation behavior at 1000 ℃ isothermal oxidation test. The aluminide coating and Al-Cr coating both possess good oxidation properties in this test. Compared with aluminide coating, Al-Cr coating exhibits much better oxidation behavior due to the formation of Cr(W) zones, which can delay the process of Al depletion by hindering the diffusion of Al from the coating to the substrate. As for 1100 ℃ isothermal oxidation test, a large amount of mixed oxides include NiCr2O4 spinel and a-Al2O3 form on the surface of DSM11 substrate. The oxide scale on the surface of aluminide coating is simplex a-Al2O3 at the initial stage, while prolonging the oxidation time it changes into less protective mixed structure composed of NiCr2O4 spinel and a-Al2O3 with massive internal oxidation, leading to great degradation and even failure of the coating. The surface of Al-Cr coating is covered with thick a-Al2O3 during the whole oxidation process. The localized scaling zones produced during oxidation are re-covered by newly formed a-Al2O3. It benefits from the third element effect of Cr, which implies that the Al-Cr coating degenerates primarily by consuming Al-reservoirs. Moreover, the presence of Cr can promote the selective oxidation of Al and the self-repair abilities of the coating.

Key words:  arc ion plating      pack cementation aluminizing      Al-Cr coating      isothermal oxidation     
Received:  19 February 2014     
ZTFLH:  TG111.5  
  TG174.44  
Fund: Supported by National Natural Science Foundation of China (No.51001106) and National Basic Research Program of China (No.2012CB625100)
About author:  null

作者简介: 吴多利, 男, 1987年生, 硕士

URL: 

https://www.ams.org.cn/EN/10.11900/0412.1961.2014.00077     OR     https://www.ams.org.cn/EN/Y2014/V50/I10/1170

Fig.1  XRD spectra of aluminized coating and Al-Cr coating
Fig.2  Cross sectional images of aluminized coating (a) and Al-Cr coating (b)
Sample Al Ti Cr Co Ni
Aluminized coating 25.6 4.5 5.3 6.8 Bal.
Al-Cr coating 31.9 0.4 13.2 6.4 Bal.
Table 1  Nominal chemical compositions of aluminized coating and Al-Cr coating
Fig.3  Isothermal oxidation kinetic curves of DSM11 substrate, aluminized coating and Al-Cr coating at 1000 ℃
Fig.4  Surface XRD spectra of DSM11 substrate, aluminized coating and Al-Cr coating after isothermal oxidation at 1000 ℃ for 20 h
Fig.5  Cross sectional images of DSM11 substrate (a), aluminized coating (b) and Al-Cr coating (c) after isothermal oxidation at 1000 ℃ for 20 h
Fig.6  Surface XRD spectra of DSM11 substrate, aluminized coating and Al-Cr coating after isothermal oxidation at 1000 ℃ for 150 h
Fig.7  Cross sectional images of DSM11 substrate (a), aluminized coating (b) and Al-Cr coating (c) after isothermal oxidation at 1000 ℃ for 150 h
Fig.8  Surface XRD spectra of DSM11 substrate, aluminized coating and Al-Cr coating after isothermal oxidation at 1000 ℃ for 300 h
Fig.9  Cross sectional images of DSM11 substrate (a), aluminized coating (b) and Al-Cr coating (c) after isothermal oxidation at 1000 ℃ for 300 h
Fig.10  Isothermal oxidation kinetic curves of DSM11 substrate, aluminized coating and Al-Cr coating at 1100 ℃
Fig.11  Surface XRD spectra of DSM11 substrate, aluminized coating and Al-Cr coating after isothermal oxidation at 1100 ℃ for 20 h
Fig.12  Cross sectional images of DSM11 substrate (a), aluminized coating (b) and Al-Cr coating (c) after isothermal oxidation at 1100 ℃ for 20 h
Fig.13  Surface XRD spectra of DSM11 substrate, aluminizedcoating and Al-Cr coating after isothermal oxidation at 1100 ℃ for 300 h
Fig.14  Surface XRD spectra of DSM11 substrate, aluminized coating and Al-Cr coating after isothermal oxidation at 1100 ℃ for 300 h
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