Abstract
β-FeAl coatings containing 5.7at.% Cr were produced with a close-field unbalanced magnetron sputter (CFUMS) deposition technique. Cyclic oxidation test at 1100°C in air for 100 1-h cycles and isothermal exposures from 1000°C through 1200°C in pure O 2 for 100 hours were carried out with the coatings. The coating showed better scale spallation resistance during cyclic oxidation test than the cast FeAl. After the isothermal oxidation at 1000°C and 1100°C, fine-grained ridge-type oxide scales were formed on the coatings, while at 1000°C, the oxide scale formed on the cast FeAl showed a large quantity of θ-Al 2 O 3 blades, and big interfacial voids on the base alloy surface were observed. The transformation from 6 to α-Al 2 O 3 was accelerated due to the presence of Cr in the coatings, and suppressed the fast outward Al diffusion for the growth of θ-Al 2 O 3 scale and eliminated the formation of interfacial voids that deteriorated the oxide scale spallation resistance. After the isothermal exposure at 1200°C, however, the oxide scale on the coating was greatly buckled and spalled, and did not show much improvement over the cast FeAl.
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