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Acta Metall Sin  2018, Vol. 54 Issue (12): 1825-1832    DOI: 10.11900/0412.1961.2018.00230
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Protection Mechanism Study of Enamel-Based Composite Coatings Under the Simulated Combusting Gas Shock
Cean GUO1,2,3, Minghui CHEN4(), Yimin LIAO4, Bei SU1, Dongbai XIE5, Shenglong ZHU2, Fuhui WANG4
1 Equipment Engineering School, Shenyang Ligong University, Shenyang 110159, China
2 Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
3 Chongqing Jianshe Industry (Group) LLC, Chongqing 400054, China
4 School of Materials Science and Engineering, Northeastern University, Shenyang 110819, China
5 Xinjiang Police College, Urumqi 830011, China
Cite this article: 

Cean GUO, Minghui CHEN, Yimin LIAO, Bei SU, Dongbai XIE, Shenglong ZHU, Fuhui WANG. Protection Mechanism Study of Enamel-Based Composite Coatings Under the Simulated Combusting Gas Shock. Acta Metall Sin, 2018, 54(12): 1825-1832.

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Abstract  

High-temperature-resistant enamel coatings have been reported to be applied in non-critical hot end components of aero-engine and gas turbine recently. Although the enamel with a series of excellent properties can be as high-temperature-resistant coating material under appropriate condition, its lower soft point and inherent brittleness limit their use in broader application under severe service condition. Enamel-based composite coatings (an enamel matrix with the addition of ceramic particles and/or metal platelets) can remarkably increase the properties of the enamel coating and their protection mechanism under dynamic thermal shock needs further investigation. In this work, two kinds of enamel-based composite coatings, 70%enamel+25%Al2O3 and 70%enamel+20%Al2O3+10%NiCrAlY (mass fraction, %) abbreviated to E25A and E20A10M respectively, were designed and fired on K38G superalloy substrate, and their protection mechanism was comparatively studied at 900 ℃ under the simulated combusting gas shock. The thermal shock fire was produced by the mixture gas of C3H8+O2 and its ejecting pressure on the coating surface was 0.4 MPa. After the temperature has been stable at 900 ℃, samples were hold for 15 s and then cooling down in air for 120 s, constituting a thermal shock cycle. Results indicated that, after 150 cyc of thermal shock, both the coatings bond well with the alloy substrate, thus shows high resistance to spallation along interface. For the E25A coating, its microstructure had no obvious change after thermal shock and the surface is still intact. The addition of secondary phase Al2O3 increases the stability of enamel at high temperature. With regard to the E20A10M coating, holes and cracks form consecutively, and peeling off occurs at surface after thermal shock. Interfacial reaction between the NiCrAlY particles and enamel following Cr(NiCrAlY)+ZnO(enamel)→CrO(interface)+Zn↑ results in the formation of enamel swelling, which then, under the synergistic effect of combusting gas shear stress and interface thermal stress, leads to the peeling off of enamel and metal inclusions at surface.

Key words:  enamel-based composite coating      high-temperature corrosion      Al2O3      NiCrAlY      thermal shock     
Received:  25 May 2018     
ZTFLH:  TG174.4  
Fund: Supported by National Natural Science Foundation of China (No.51471177), Fundamental Research Funds for the Central Universities (No.N160205001) and National Science Foundation of Liaoning Province of China (No.201602643)

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https://www.ams.org.cn/EN/10.11900/0412.1961.2018.00230     OR     https://www.ams.org.cn/EN/Y2018/V54/I12/1825

Fig.1  Schematic of sample geometrical shape (unit: mm)
Fig.2  Surface (a) and cross-sectional (b) morphologies of the as-fired E25A coating
Fig.3  Surface (a) and cross-sectional (b, c) morphologies, and line scanning EDS (d) of the E25A coating after 150 cyc of combusting gas shock at 900 ℃
Fig.4  Surface (a) and cross-sectional (b) morphologies of the as-fired E20A10M coating
Fig.5  Surface (a) and cross-sectional (b) morphologies of the E20A10M coating after 150 cyc of combusting gas shock at 900 ℃
Fig.6  Local typical failure of NiCrAlY particle detachment (a) and enamel block crack (b) of the E20A10M coating after 150 cyc of combusting gas shock at 900 ℃
Fig.7  Schematics of network structure of glass (a) and glass with Al2O3 (b)
Fig.8  Thermal expansion curves of the enamel and its composites E25A and E20A10M (?L—direct increment of length, L—initial length)
Fig.9  Schematics showing failure mechanism of a big NiCrAlY particle (a) and several closely distributed small NiCrAlY particles (b) of the E20A10M coating (T—temperature)
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