Oxidation of Al2O3 Scale-Forming MAX Phases in Turbine Environments

Abstract

High temperature oxidation of alumina-forming MAX phases, Ti2AlC and Cr2AlC, were examined under turbine engine environments and coating configurations. Thermogravimetric furnace tests of Ti2AlC showed a rapid initial transient due to non-protective TiO2 growth. Subsequent well-behaved cubic kinetics for alumina scale growth were shown from 1273 K to 1673 K (1000 °C to 1400 °C). These possessed an activation energy of 335 kJ/mol, consistent with estimates of grain boundary diffusivity of oxygen (~375 kJ/mol). The durability of Ti2AlC under combustion conditions was demonstrated by high pressure burner rig testing at 1373 K to 1573 K (1100 °C to 1300 °C). Here good stability and cubic kinetics also applied, but produced lower weight gains due to volatile TiO(OH)2 formation in water vapor combustion gas. Excellent thermal stability was also shown for yttria-stabilized zirconia thermal barrier coatings deposited on Ti2AlC substrates in 2500-hour furnace tests at 1373 K to 1573 K (1100 °C to 1300 °C). These sustained a record 35 µm of scale as compared to 7 μm observed at failure for typical superalloy systems. In contrast, scale and TBC spallation became prevalent on Cr2AlC substrates above 1423 K (1150 °C). Cr2AlC diffusion couples with superalloys exhibited good long-term mechanical/oxidative stability at 1073 K (800 °C), as would be needed for corrosion-resistant coatings. However, diffusion zones containing a NiAl-Cr7C3 matrix with MC and M3B2 particulates were commonly formed and became extensive at 1423 K (1150 °C).