A single step process to form in-situ an alumina foam/aluminide TBC system for alloys in extreme environments at high temperatures

Abstract

A new approach to manufacture a complete thermal barrier coating system in a single step is studied in the frame of the European FP7 project PARTICOAT. Spherical μm-Al particles are deposited on different substrate alloys. During the sintering process in air, the μm-Al particles are oxidized and converted into hollow alumina spheres forming a ceramic “foam” (top coat), and simultaneously an Al rich diffusion layer (bond coat) is formed in the subsurface zone of the substrate.The “green” coatings deposited by air brush on IN738, René80 and CM247 nickel based alloys were cured at 300°C and then isothermally exposed at 800 and 1000°C in air for up to 1000h. The oxide formation and the microstructure of the coatings were studied by thermo gravimetrical analysis (TGA), X-ray diffraction (XRD), scanning electron microscopy combined with energy dispersive X-ray spectroscopy (SEM-EDX).The coatings were adherent for all the substrates and temperatures tested. René80 shows the lowest mass gain whereas IN738 and CM247 show higher mass gains at the temperatures studied. Additionally, the use of reactive element oxides in the coating was investigated, demonstrating the flexibility and viability of this low cost coating concept.