Alumina formation and microstructural changes of aluminized CoNiCrAlY coating during high temperature exposure in the temperature range 925°C–1075°C

Abstract

MCrAlY (M = Ni, Co) coatings are commonly used on gas-turbine components as oxidation resistant overlay coatings and bondcoats for thermal barrier systems. In the present work the microstructural features and oxidation behavior of an aluminized Co-base MCrAlY-coating on a Ni-based superalloy have been investigated in the temperature range 925–1075 °C. Microstructural studies of the oxidized coatings by SEM/EBSD were complemented with numerical thermodynamic calculations using the software package ThermoCalc. In the as-received condition the outer part of the coating consisted mostly of β-(Ni,Co)Al. Formation of σ-CoCr was observed at the interface between the β-layer and the inner initial CoNiCrAlY. During high-temperature air exposure alumina based surface scales were formed but the oxidation induced Al depletion of the aluminized coating did not result in formation of the γ’-(Ni3Al) phase. Rather, the subscale formation of Co/Cr-rich phases was observed and a direct transformation of β- into γ-Ni phase after longer times. It is expected that these subscale microstructural changes thus affect the alumina formation and growth as well as the critical aluminum depletion in a different manner as in the case of corresponding β-NiAl coatings, although a direct comparison between various coating systems was not possible on the basis of the present results.