Hengrong Guan

Effect of the θ–α-Al2O3 Transformation in Scales on the Oxidation Behavior of a Nickel-Base Superalloy with an Aluminide Diffusion Coating

The high-temperature oxidation behavior of a nickel-base superalloy andaluminide-diffusion coating has been investigated over the temperaturerange from 800–1100°C and analyzed by TGA, XRD, EDAX, andSEM. The β-NiAl coating was formed by low-pressure gas-phasecementation at 950°C for 3 hr. It was found that the formation ofα-Al2O3 from θ-Al2O3 on the β-NiAl coating resulted in asharp decrease in the parabolic rate constant kp by one order ofmagnitude at 1050°C during transient oxidation. The transformationcaused the anomalous behavior of the oxidation kinetics curves of thisdiffusion coating in the temperature range 800–1100°C withinthe first 100 hr. A change in the morphology of scales also occurredwith the transformation. A growth stress was characterized by theformation of convoluted scales, which were observed on the surfaceafter oxidation. The oxidation mechanism of this β-NiAl diffusioncoating is described.

Oxidation behavior of sputtered microcrystalline coating of superalloy K17F at high temperature

The influence of sputtering on the high temperature oxidation resistance of the cast superalloy M17F has been studied. The as-sputtered microcrystalline layer has a homogeneous gamma phase structure with very fine gl ain size (20-100 nm), while the as-cast alloy is composed of gamma, gamma and carbides. The oxidation resistance of the microcrystalline coating of K17F alloy is much better than that of the as-cast alloy, and is even superior to that of the pack aluminized alloy. At the initial oxidation stage, the oxide scale which formed on the as-cast alloy is composed of complex oxides of Cr, Ti, Ni and Al. As the: oxidation time is prolonged, the amount of alpha-Al2O3 increases and becomes the main product. However, the scale which formed on the microcrystalline coating consists only of alpha-Al2O3. Cyclic oxidation and acoustic emission examination showed that the oxide scale on the cast M17F alloy easily spalled during cooling, but the alpha-Al2O3 scale on the sputtered layer had excellent adhesion. The beneficial effects of microcrystalline structure on oxidation resistance are discussed briefly.

A comparative study of DS NiCrAlY coating and LPPS NiCrAlY coating

Abstract Two thermal spraying techniques, namely, detonation gun spraying (DS) and low pressure plasma spraying (LPPS), were used to prepare different NiCrAlY coatings on a single crystal (SC) Ni-based superalloy. Microstructure, surface hardness, adhesion strength and high-temperature oxidation behavior of DS NiCrAlY coating and LPPS NiCrAlY coating were compared. The results showed that the two coatings in as-sprayed state had the same splat layer structure. Somewhat differently, oxidation reaction took place in DS process and Al2O3 sandwiched between the splats in DS NiCrAlY coating. It is found that the surface hardness of DS coatings are higher than those of LPPS coating. But the oxidation resistance of DS coating is relatively lower.

1050 °C isothermal oxidation behavior of detonation gun sprayed NiCrAlY coating

NiCrAlY coating was deposited on a single crystal Ni-base superalloy by detonation gun spraying. By means of XRD, SEM and EDS, isothermal oxidation behavior of the coatings at 1050 degreesC were studied. The results showed that detonation gun sprayed NiCrAlY coatings held a favorable oxidation resistance. Their oxidation kinetics at 1050 degreesC obeyed the parabolic law. alpha-Al2O3 scale was formed on the coating surface and kept almost intact after oxidation for 300 It. Internal oxidation led to the formation of Al2O3 at the coating/substrate interface, and needlelike (Al, N) compounds appeared in the undersurface area of the substrate

Oxidation and Degradation of EB–PVD Thermal–Barrier Coatings

Thermal–barrier coatings (TBCs) consist of a magnetron-sputtered Ni–30Cr–12Al–0.3Y (wt.%) bond coat to protect the substrate superalloy from oxidation/hot corrosion and an electron-beam physical-vapor deposited (EB–PVD) 7 wt.% yttria partially stabilized zirconia (YPSZ) top coat. The thermal cyclic life of the TBC system was assessed by furnace cycling at 1050°C. The oxidation kinetics were evaluated by thermogravimetric analysis (TGA) at 900, 1000, and 1100°C for up to 100 hr. The results showed that the weight gain of the specimens at 1100°C was the smallest in the initial 20 hr, and the oxide scale formed on the sputtered Ni–Cr–Al–Y bond coat is only Al2O3 at the early stage of oxidation. With aluminum depletion in the bond coat, NiO, Ni(Cr,Al)2O4, and other spinel formed near the bond coat. During thermal cycling, microcracks were initiated preferentially in the YPSZ top coat along columnar grain boundaries and then extended through and along the top coat. The growth stress of TGO added to the thermal stress imposed by cycling, lead to the separation at the bond coat–TGO interface. The ceramic top coat spalled with the oxide scale still adhering to the YPSZ after specimens had been cycled at 1050°C for 300 cycles. The failure mode of the EB–PVD ZrO2–7 wt.% Y2O3 sputtered Ni–Cr–Al–Y thermal-barrier coating was spallation at the bond coat–TGO interface.

Secondary M6C precipitation in K40S cobalt-base alloy

Secondary M,C precipitation was investigated in K40S cobalt-base alloy after 100 h aging at 950 degreesC. The results showed that it was closely related to the tungsten-rich zones inherited from the as-cast condition and the degeneration of the primary M7C3 carbide. A direct element reaction, 6M + C --> M6C, in which C comes from the decomposition of the M7C3 carbides, is suggested as the mechanism of secondary M6C precipitation in K40S alloy

Thermo-mechanical fatigue of single crystal nickel-based superalloy DD8

The thermo-mechanical fatigue (TMF) behavior and the relevant microstructural evolution of the single crystal nickel-based superalloy DD8 were investigated. In-phase TMF lives were much shorter than those of out-of-phase TMF. The mechanism of TMF damage is discussed based on the microstructural evolution during TMF

Carbide behaviour during high temperature low cycle fatigue in a cobalt-base superalloy

The carbide behaviour of a directionally solidified cobalt-base superalloy has been investigated after low cycle fatigue at 900°C. During fatigue, primary carbides, M7C3 and MC, decomposed sluggishly and a great amount of secondary carbide, chromium-rich M23C6 precipitated. The inhomogeneous distribution of M23C6 brought about a different dislocation substructure. In the vicinity of the primary carbides, densely-distributed fine M23C6 pinned up dislocations effectively, resulting in a uniform distribution of dislocations, while in the interior of grains, since precipitates were coarse and scarce, dislocations were arranged in a planar array and piled up in the front of the precipitates. M23C6 also acted as an obstacle deflecting fatigue crack. Primary carbides on the surface of specimens were oxidizied preferentially, causing a precipitate depletion around them. The oxidized primary carbides were crack initiation sites. The primary carbides hindered fatigue crack propagation, causing the formation of shear steps.

Cyclic oxidation behavior of aluminide coatings on the Co-base superalloy DZ40M

Aluminide coatings are prepared on a new Co-base superalloy DZ40M by low-pressure chemical vapor deposition (LP-CVD), and their cyclic oxidation behavior is investigated. The results show that the coating degradation primarily results from Al-depleting to heal the oxide scale on the outer surface during the cyclic oxidation, unlike that primarily from inward Al diffusion to the substrate during the isothermal process. The effect of Ti on the oxidation resistance is very different for various intermetallic alloys, and the addition of Ti will increase the degradation for the present coating during high-temperature oxidation. These experimental results are helpful to clarify the understanding of the Ti-modification effect on aluminide coatings for Co-based superalloys.

Roles of Zr and Y in cast microstructure of M951 nickel-based superalloy

The influence of Zr and Y on the cast microstructure of a nickel-based superalloy was investigated by optical microscopy (OM), scanning electron microscopy(SEM), electron probe micro-analysis (EPMA) and X-ray diffraction (XRD). The gamma+gamma eutectic volume in the superalloy rises notably with the increase of Zr or Y content. Meanwhile, the morphologies of primary MC carbides change from needle and platelet-like to blocky shape with increasing Zr and Y doped. The XRD results show that the primary MC carbide lattice constant increases with Zr and Y additions, and EPMA investigation shows that the platelet-like MC carbides contain primarily Nb and C, while those carbides in blocky shape have 39.2% Zr and 39.6% Nb in average,. These influences on the cast microstructure can be attributed to the atomic size effects of Zr and Y.