Evaluation of aluminide diffusion coatings for thermal cyclic oxidation protection of a nickel-base superalloy

Abstract

Active element modified aluminide diffusion coatings on IN738 substrates were produced by a new route using continuously cast, aluminum alloy wires consisting of Al-Y, Al-Ce, Al-La and Al-Si-Y. The cast wires were used as evaporation sources for ion-vapour deposition followed by diffusion heat treatments to form nickel aluminide coatings. In order to examine the oxidation resistance of these coatings at elevated temperatures, thermal cyclic oxidation experiments were carried out in air at 1050°C. While all coatings were found to provide significant protection, the Al-La modified coatings provided the greatest resistance to cyclic oxidation. On the other hand, with coatings based on Al-Si-Y alloys, while silicon has a strong ability to reduce the outward diffusion of aluminum, the adverse effect of silicon on mechanical properties of the coating, together with the formation of volatile silicon monoxide, led to catastrophic localized oxidation of the protective coatings.