Changes of an Outer β-NiAl and Inner α-Cr Coating on Ni–40 at% Cr Alloy during Oxidation at 1373K in Air

Abstract

Formation mechanisms of a coating with a duplex layer, outer β-NiAl(Cr) and inner α-Cr(Ni) layer structure on a Ni–40.2 at% Cr alloy were proposed and change in the coating structure was investigated during high temperature oxidation. The Ni–40.2 at% Cr alloy was electro-plated with about 12μm Ni followed by a high Al activity pack cementation at 1073K to form a coated layer with an outer δ-Ni2Al3 and an inner layer containing Al more than 70at% which grew with an inward diffusion of Al. The coated Ni–40.2at% Cr alloy was oxidized at 1373K in air for up to 2592ks. It was found that at the initial stage of oxidation the as-coated layer structure changed to a two-layer, outer β-NiAl(Cr) and inner α-Cr(Ni), structure. Al contents in the α-Cr(Ni) layer was less than 0.3at%. With long term oxidation an intermediate γ-Ni(Cr, Al) layer formed between the outer and inner layers, whereas the inner α-Cr(Ni) layer became thinner and then disappeared after the 2592ks oxidation at 1373K. Coating processes and changes in the coating structure during high temperature oxidation were discussed based on diffusion and composition paths plotted on a Ni–Cr–Al phase diagram