Exploring the effect of Si content in Cr coating on its microstructure and properties

Abstract

Four CrSi coatings with varying Si content ranging from 2 at.% to 9 at.% were deposited on the both surface of Zr-4 substrate. This study systematically investigated the effect of Si content on microstructure, mechanical properties, corrosion resistance and high-temperature oxidation resistance. Due to the lower Si content, only the Cr phase was detected in the CrSi coating, with Si existing in solid-solution. Therefore, all CrSi coatings exhibited good mechanical and hydrophobic properties. The addition of Si in the Cr coating significantly reduces the surface roughness compared with Cr coating. During the long-term autoclave test (30-day, 60-day and 90-day) at 320 °C and 11.3 MPa, CrSi coatings demonstrated superior corrosion resistance attributed to the effective inhibition of further Si dissolution by the dense and continuous Cr2O3 layer forming on the surface. Additionally, after exposure to high-temperature oxidation at 1200 °C for 30 min, all CrSi coatings protect the substrate from oxidation. However, only the Cr0.91Si0.09 coating internally formed a dense and continuous in-situ Zr2Si diffusion barrier layer, which effectively reduce the Cr/Zr inter-diffusion, and sufficient Si prevent the outwards diffusion of Cr by forming Cr3Si boundary. The corrosion and oxidation mechanism have been studied in detail.