Investigation on the interdiffusion mechanism between single-crystal superalloy and FeCrNiAl-based medium entropy alloys

Abstract

High and medium entropy alloys (HEAs, MEAs) have emerged as promising candidates for bond-coat materials in the thermal barrier coating systems due to their exceptional oxidation resistance. However, understanding the interdiffusion behavior between these alloys and single-crystal superalloys (SXs) substrates requires further investigation. In this study, diffusion couples were created between SXs and two types of MEAs, namely FeCrNiAl and FeCrNi0.4Al0.4, and the interdiffusion behavior was simulated using the commercial DICTRA code. The results reveal significant interdiffusion at 1100 °C in the couples, attributed to the substantial elemental differences between SXs and MEAs. This led to the formation of the interdiffusion zone (IDZ) and the secondary reaction zone (SRZ). Within the SRZ, phase transformation of SXs occurred, resulting in the precipitation of topologically close-packed (TCP) phases. Three types of TCP phases (σ, μ, and P) were observed. Along the {11¯02} plane of the μ phase, twins and stacking faults have formed. The glide of P phase contributed to the bending of bar-like precipitates. Notably, the amorphization of the σ phase was observed for the first time, suggesting an intermediate state during the phase transformation. Despite elemental differences between the two MEAs, the growth mechanism of IDZ and SRZ, as well as the precipitation of TCP phases, exhibited similarities. This underscores the importance of Cr and Ni diffusion alongside Al diffusion. The pronounced interdiffusion behavior raises concerns about the suitability of 3-d transition metal MEAs as bond-coat materials due to the lack of slow diffusion effect.