Hot Corrosion Behavior of DZ411 Nickel-Based Superalloy NiCoCrAlY Coating at 950 oC
Received date: 2024-11-21
Revised date: 2025-01-06
Online published: 2025-05-07
Supported by
Basic Research Project for Marine Gas Turbines(MGT2023001)
NiCoCrAlY coatings offer good resistance to high-temperature oxidation and corrosion, making them an effective protective layer for gas turbine blades. However, in marine environments, these coatings are susceptible to hot corrosion damage, considerably affecting service lifespan and safety. With the development of modern gas turbines with high efficiency and power, the service temperatures of their blades have increased. An in-depth understanding of the hot corrosion mechanisms of NiCoCrAlY coatings above 900 oC is crucial for developing advanced gas turbine blade materials suitable for marine applications. This study investigates the hot corrosion kinetics using conventional gravimetric analysis while considering the quality effect of molten salt volatilization. XRD, SEM, and EDS were used to analyze the surface and interface microstructures, as well as the compositional characteristics of the NiCoCrAlY coating on the DZ411 alloy. These analyses were performed after exposure at 950 oC under a Na2SO4 salt film and a mixed salt film comprising Na2SO4 and NaCl. Results demonstrated that after modifying conventional hot corrosion mass-loss kinetics to consider molten salt volatilization, the hot corrosion mass change becomes a mass gain. The mass gain rate was higher in mixed salt environments than in pure sulfate environments. The hot corrosion mass gain of the alloy is attributed to cyclic oxidation-sulfidation reactions in the coating. Cross-sectional analysis of the corrosion product layer revealed a similar structure under both salt conditions: an outer layer of Al2O3, a middle layer of porous oxides dominated by Al2O3 and Cr2O3, and an inner interdiffusion zone. In addition, Al2S3 and Cr2S3 precipitates were present at the coating-substrate interface. Furthermore, the presence of chloride salt in the mixed salt environment facilitated chlorination reactions, promoting the diffusion of sulfur and oxygen, and accelerating the degradation of the coating compared with the pure sulfate condition.
Key words： NiCoCrAlY coating; DZ411 alloy; hot corrosion; diffusion
DENG Gaping , ZHAO Jie , GAO Kai , WANG Wei , LIU Huan , CAO Tieshan , CHENG Congqian . Hot Corrosion Behavior of DZ411 Nickel-Based Superalloy NiCoCrAlY Coating at 950 oC[J]. Acta Metall Sin, 2026 , 62(6) : 1059 -1068 . DOI: 10.11900/0412.1961.2024.00398
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