In this study, the isothermal oxidation behaviors of HEA coating systems with AlCoCrFeNiTi and AlCoCrFeNiZr contents were evaluated by comparing microstructurally and investigated in terms of potential applications of thermal barrier coatings (TBCs). For this reason, their oxidation resistance under isothermal conditions, as well as diffusion phenomena occurring at the bond and top coating interface, were investigated. CoNiCrAlY bond coating was applied to the surface of a Nickel-based superalloy substrate by high velocity oxygen-fuel (HVOF) spraying. HEA coating materials were produced by using the mechanical alloying (MA) process. The mechanical activated synthesized HEAs were sprayed on a CoNiCrAlY bond coating by Atmospheric Plasma Spraying (APS). The microstructural changes at the coating interface of CoNiCrAlY, AlCoCrFeNiTi and AlCoCrFeNiZr (HEAs) coatings resulting from oxidation processes at 1200 °C for 5, 25, 50 and 100 h, and the formation and growth behaviors of the thermally grown oxide (TGO) layer were investigated. The present results demonstrate a potential of HEAs in TBC applications. After oxidation tests, crystal lattice transformations took place in both coating systems. In the AlCoCrFeNiZr-HEA TBC system, an increase in diffusion rate, oxygen permeability, and consequently TGO layer thickness was observed by the transformation from the cubic lattice structure to a monoclinic lattice structure with a larger volume. In the AlCoCrFeNiTi-HEA TBC system, the transformation of a narrow rhombohedral lattice with tight planes was maintained. Therefore, the TBC system with AlCoCrFeNiTi-HEA has a lower TGO layer thickness compared to the TBC system with AlCoCrFeNiZr-HEA and has a longer service life against oxidation failure at high operating temperatures. As a result of the production, experimental studies and high temperature oxidation test studies under service conditions, it was seen that AlCoCrFeNiTi and AlCoCrFeNiZr-HEA coatings can be used in the structure of TBC systems.
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