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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 JIANG1,2, 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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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-Al2O3 simultaneously. 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

Cite this article: 

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.

URL: 

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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