Abstract
Two MCrAlX powders with different Fe content were deposited on an IN792 superalloy using high velocity oxygen-fuel spraying (HVOF). The oxidation and interdiffusion behaviour of the coated specimens were investigated at 900, 1000 and 1100 °C for different exposure times. Experimental results showed that high Fe addition in the MCrAlX coating had no obvious effect on oxidation, however, a great impact on coating-substrate interdiffusion and coating degradation was observed. Although no influence on Al diffusivity in IN792, high Fe addition promotes the formation of a discontinuous σ phase layer at the coating/substrate interface, which retards Al diffusion in the IN792 substrate at 900 °C. To investigate Fe influence on phase equilibrium, thermodynamic calculation was also performed. It was shown that high Fe addition in the MCrAlX coating increased the β phase fraction and stabilized the β phase by extending the β + γ phase region. Besides, high Fe addition in the MCrAlX coating modifies Cr diffusion, and alters local phase equilibrium at the coating/substrate interface. These two factors suppress inner-β depletion of high Fe containing coating. Grain coarsening of the coating can be observed during oxidation, it was retarded by high Fe addition.
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