Advances in Diffusion Barrier Coatings for High-Temperature Applications

Abstract

Diffusion barrier coating (DBC) systems on heat resistant alloys consist of a multi-layer structure: an outer Al-reservoir layer and an inner diffusion barrier layer (DBL). The outer Al-reservoir layer forms a protective Al2O3 scale and DBL acts as a barrier layer against alloy interdiffusion. Three kinds of DBL were developed: Re on Ni-based superalloys; W on stainless steels; and Cr on Ni–Cr alloys. It was found that DBC systems have excellent mechanical properties (creep and fatigue), improving alloy substrate performance, and enhance the anti-exfoliation properties of YSZ in thermal barrier coatings (TBC) in addition to providing excellent oxidation resistance. At temperatures higher than 1300 °C, however, the DBC design based on kinetics (diffusion) is insufficient to form and maintain a protective Al2O3 scale. In this case a self-maintaining coating (SMC) system designed on the basis of thermodynamics (phase stability) is required. The SMC system formed on Nb–Hf (C-103) alloy consists of a multi-layer structure: an outer Re (Al, Si)1.8 and inner NbSi2 layers, plus a transient Nb5Si3 layers formed during oxidation. At temperatures higher than 1300 °C the Al2O3 can be formed by changing the Al/Si ratio in the Re (Al, Si)1.8 in which Si was supplied from the decomposition reaction of NbSi2 to Si + Nb5Si3 during selective oxidation of Al. It is proposed that coating alloys should be designed for considering not only high temperature oxidation, but also alloy substrate mechanical properties and anti-exfoliation of oxide scales, based on both kinetic principles (DBC system) and thermodynamics (SMC system).