NiCrAlY Coatings Research Articles

Effect of Vacuum Heat Treatment on the High-Temperature Oxidation Resistance of NiCrAlY Coating

NiCrAlY coatings were prepared using high-velocity oxygen fuel spraying (HVOF), and the coatings were removed from the substrate to achieve a uniform shape. Vacuum heat treatment (VHT) of the as-sprayed coatings was conducted at different temperatures (1000, 1100, and 1200 °C), and the specimens were subjected to isothermal oxidation exposure testing in air at 1100 °C for up to 21 h. The results show that the high temperature oxidation resistance of the coating increased gradually with the increase in VHT temperature, and the coating of VHT1200 had higher oxidation resistance. The high temperature oxidation resistance of the coating was related to the microstructure transformation of the coating. In VHT coatings, β-NiAl became a dispersed irregular block morphology. The γ’-Ni3Al in VHT1000 presented a granular morphology. However, in VHT1100 and VHT1200, γ’-Ni3Al became a lamellar morphology. This transformation of microstructure promotes the form of exclusive α-Al2O3 scale. With the increase in VHT temperature, the content of yttrium on coatings’ surface was increased and the pores were gradually eliminated. The concentration of yttrium on coatings’ surface prevented the formation of θ-Al2O3 and low porosity was beneficial in improving the internal oxidation of the coating.

Effect of electro-codeposition parameters on particle incorporation in Ni-CrAlY(Ta) coatings

ABSTRACT Electrolytic codeposition is a promising alternative low-cost process for fabricating MCrAlY coatings. In this process, CrAlY particles are codeposited with the (Ni,Co) to form an (Ni,Co)-CrAlY composite coating, which is subsequently heat treated at elevated temperatures to be transformed to the MCrAlY coating containing phases of β-NiAl, γ-(Ni,Co), etc. A permeable rotating barrel was utilized in the present electro-codeposition process, which offered the benefit to apply uniform coatings on the entire sample surface. Such codeposition configuration allowed exchange of electrolyte between the barrel and the plating tank while keeping the specimen and powder inside the barrel. Two types of CrAlY-based particles (made by ball milling and gas atomization) were employed. The effects of several key processing parameters, such as current density, particle loading, and barrel rotational speed, on the CrAlY(Ta) particle incorporation in the electrodeposited Ni-CrAlY(Ta) coatings were studied. The influence of particle geometry/shape was also investigated. Higher CrAlY particle incorporation was observed for the spherical gas-atomized particles than the ball-milled particles with irregular shapes.

An in-situ formed ceramic/alloy/ceramic sandwich barrier to resist elements interdiffusion between NiCrAlY coating and a Ni-based superalloy

NiCrAlY coatings are widely applied on various alloy components to enhance oxidation and/or corrosion resistance at high temperatures. However, elements interdiffusion occurs between them due to composition difference. Although various diffusion barriers (DBs) are reported, this problem is still far from completely solved as most ceramic barriers suffer from poor adherence, while the metallic barriers play a limited role. In this study, NiCrAlY coating was deposited onto a second-generation single-crystal superalloy by arc ion plating. A novel simple method is provided to address elements interdiffusion. By pre-oxidation at a moderate temperature, a thin scale of Ni(Co)O forms at the alloy surface. It transforms to be an alumina/NiCoCr alloy/alumina sandwich by an in-situ reaction with the overlaying NiCrAlY coating and the alloy substrate at high service temperatures, which offers good barrier ability in conjunction with strong adhesion. In the presence of such an alumina/alloy/alumina DB, the NiCrAlY coating provides high resistance to oxidation and scale spallation for the alloy substrate.

Cavitation Erosion and Sliding Wear of MCrAlY and NiCrMo Coatings Deposited by HVOF Thermal Spraying

Abstract The investigation into wear resistance is an up-to-date problem from the point of view of both scientific and engineering practice. In this study, HVOF coatings such as MCrAlY (CoNiCrAlY and NiCoCrAlY) and NiCrMo were deposited on AISI 310 (X15CrNi25-20) stainless steel substrates. The microstructural properties and surface morphology of the as-sprayed coatings were examined. Cavitation erosion tests were conducted using the vibratory method in accordance with the ASTM G32 standard. Sliding wear was examined with the use of a ball-on-disc tribometer, and friction coefficients were measured. The sliding and cavitation wear mechanisms were identified with the SEM-EDS method. In comparison to the NiCrMo coating, the MCrAlY coatings have lower wear resistance. The cavitation erosion resistance of the as-sprayed M(Co,Ni)CrAlY coatings is almost two times lower than that of the as-sprayed NiCrMoFeCo deposit. Moreover, the sliding wear resistance increases with increasing the nickel content as follows: CoNiCrAlY < NiCoCrAlY < NiCrMoFeCo. The mean friction coefficient of CoNiCrAlY coating equals of 0.873, which almost 50% exceed those reported for coating NiCrMoFeCo of 0.573. The as-sprayed NiCrMoFeCo coating presents superior sliding wear and cavitation erosion resistance to the as-sprayed MCrAlY (CoNiCrAlY and NiCoCrAlY) coatings.

Preparation, characterization and oxidation behavior of CeO2-gradient NiCrAlY coatings applied by HVOF thermal spraying process

Conventional and CeO2-gradient NiCrAlY coatings (0.5–2.0 wt% of nano-CeO2 from the inner layer to layers adjacent to the outer surface) were produced by the high-velocity oxy-fuel spraying (HVOF) process. Microstructural characteristics, phases analysis and high-temperature oxidation behavior of the functionally graded (FG) NiCrAlY/nano-CeO2 coatings were investigated and compared with those monolayer (ML) NiCrAlY coatings with without CeO2 nanoparticles. The microstructure of the ML- and FG-coatings, as well as processed powders, were characterized using a transmission electron microscope (TEM), field emission scanning electron microscope (FESEM), energy-dispersive X-ray spectroscopy (EDS), X-ray diffraction analysis (XRD), microhardness testing and Raman spectroscopy. On account of the calculation of oxidation behavior of the coating, the ML- and FG-coatings were exposed to laboratory's air at 1000 °C up to 100 h (short-term exposure) and 5000 h (long-term exposure) and moreover, the weight gain versus oxidation time and oxide growth rate were subsequently examined. Obtained results indicated that FG-NiCrAlY/nano-CeO2 coating had a better oxidation resistance as well as a lower oxide growth rate compared to the rest of the ML-coatings. In addition, increasing oxidation resistance of FG-NiCrAlY/nano-CeO2 coating can be attributed by controlling Al and O diffusion due to the formation of relatively thin, dense, and sticky Al2O3 oxide scale. Besides, all cases of the oxidized ML- and FG-coatings had a parabolic rate behavior owing to their diffusion-controlled oxidation under short- and long-term oxidation tests.

Tribocorrosion Properties of NiCrAlY Coating in Different Corrosive Environments.

Atmospheric plasma spraying (APS) was taken to fabricate the NiCrAlY coating. The corrosion-wear properties of NiCrAlY coating was measured respectively under deionized water, artificial seawater, NaOH solution and HCl solution. Experimental results presented that the as-sprayed NiCrAlY coating consisted of Ni3Al, nickel-based solid solution, NiAl and Y2O3. In deionized water, the coating with the lowest corrosion current density (icorr) of 7.865 × 10−8 A/cm2 was hard to erode. Meanwhile, it presented a lower friction coefficient and the lowest wear rate. In HCl solution, NiCrAlY coating gave the highest corrosion current density (icorr) of 3.356 × 10−6 A/cm2 and a higher wear rate of 6.36 × 10−6 mm3/Nm. Meanwhile, the emergence of Al(OH)3 on the coating surface could reduce the direct contact between the counter ball and sample effectively, which was conducive to the lowest friction coefficient of 0.24.

Thermal cycling damage in pre-oxidized plasma-sprayed MCrAlY + YSZ thermal barrier coatings: Phenomenon of multiple parallel delamination of the TGO layer

This paper focuses on thermal cycling failure of pre-oxidized plasma-sprayed thermal barrier coatings (TBCs) with NiCrAlY and NiCoCrAlY bond-coats and yttria-stabilized zirconia (YSZ) top-coats. Pre-oxidation of full NiCrAlY + YSZ and NiCoCrAlY + YSZ TBC systems to the thickness of the thermally grown oxide (TGO) of ~3 μm was carried out mainly to reduce the influence of initial residual stresses related to the plasma spraying process. The NiCoCrAlY coatings were found to be rougher than the NiCrAlY coatings, the arithmetic average roughness Sa being nearly two times higher and the relative surface area RS being, respectively, ~1.8 and ~1.5 for the as-sprayed coatings. It was interesting to observe that despite much greater roughness of its bond-coat, the thermal cycling life of NiCoCrAlY + YSZ TBC system was more than a factor of two shorter when cycled at 1050 °C and still only comparable when cycled at 1150 °C. This resulted from much larger portion of the interface being influenced by repeated delamination of the TGO layer from the bond-coat, which formed multiple parallel alumina fragments of similar thickness. Most likely, the major cause for such behaviour was the higher thermal expansion of the NiCoCrAlY bond-coat and its higher oxidation rate, although the effect of the interfacial geometry certainly cannot be excluded.

Microstructural characterization of laser-cladded NiCrAlY coatings on Inconel 625 Ni-based superalloy and 316L stainless steel

A detailed characterization of the primary microstructure of laser-cladded NiCrAlY coatings deposited on two different substrate materials is presented in this article. Amdry 962 powder was used to deposit coatings by LENS (Laser Engineered Net Shaping) on Inconel 625 Ni-based superalloy and 316L stainless steel. An overall characterization of coatings was performed from a qualitative point of view with particular attention paid to cracks and pores. A description of microstructural aspects of the internal morphology of coatings, such as the microstructure, chemical, and phase composition were also investigated. The distribution of alloying elements, such as Fe, Mo, Nb, and Y, was investigated in cladded coatings on two different substrates. It was revealed that the cladded coatings contained cracks and gas voids typical for laser-cladding processes. The dendritic microstructure was the result of rapid solidification due to differences in the chemical composition of dendritic and interdendritic areas, which was related mainly to the yttrium concentration. Additionally, epitaxial growth during the initial stages of solidification was determined to be related to the diffusion of substrate alloying elements into the dilution zone. The strong influence of substrate materials, especially iron, in the final microstructure of coatings was analyzed. The oxidation of yttrium and the formation of Y-Al-O oxides were also analyzed.

Influence of Heat Treatment on Corrosion–Wear Behavior of Ni-Based Coating in Artificial Seawater

NiCrAlY coatings were fabricated by atmospheric plasma spraying. The influence of the heat treatment on the corrosion–wear behavior of the coatings in artificial seawater was investigated. The microstructure of the coatings became denser and more homogeneous after the heat treatment. After heat treatment at 1100 °C, the coating had the fewest pores and cracks and the oxide dispersive strengthening phase of Y2O3 was clearly increased to form a layer approximately 10 nm thick and uniformly distributed in the matrix. The heat treatment effectively improved the microhardness and corrosion–wear properties of the coatings. This coating had the highest microhardness of 371.1 HV, the lowest friction coefficient, and a wear rate of 0.24 and 1.01 × 10−6 mm3/Nm and the lowest corrosion rate after heat treatment at 1100 °C, giving it excellent corrosion–wear properties.

Tribological Performance of a Ni-Based Composite Coating in Artificial Seawater

NiCrAlY and NiCrAlY-Mo coatings were fabricated by atmospheric plasma spraying (APS). The corrosion-wear performance of the coatings was investigated in artificial seawater and the synergistic mechanism between wear and corrosion were evaluated in detail. Results showed that the diffraction peaks of Ni3Al shifted to the right and the microhardness of the coating was improved from 329.8 HV to 342.5 HV with adding the Mo element. Meanwhile, the NiCrAlY-Mo coating had a lower friction coefficient, with a wear rate of 0.26 and 3.69 × 10−6 mm3/Nm, compared to the NiCrAlY coating with a wear rate of 0.37 and 4.67 × 10−6 mm3/Nm. The NiCrAlY coating had severe corrosion and the corrosion mainly occurred in grain boundary. Adding the Mo element, the Mo element was distributed in the grain boundary and the coating had a lower corrosion rate and visibly slighter corrosion. The NiCrAlY-Mo coating had excellent corrosion-wear properties in artificial seawater.

High-temperature corrosion performance of HVAF-sprayed NiCr, NiAl, and NiCrAlY coatings with alkali sulfate/chloride exposed to ambient air

The high-temperature corrosion of high velocity air-fuel (HVAF) thermal spray Ni21Cr, Ni5Al, and Ni21Cr7AlY coatings was investigated at 600 °C for 168 h in ambient air under KCl and 50-50 mol% KCl–K2SO4 salts. Chlorination-oxidation cycle and breakdown of the corrosion products layer were the dominant corrosion mechanism in the chromia-forming Ni21Cr and Ni21Cr7AlY coatings exposed to KCl. KCl–K2SO4 was less corrosive to the chromia-forming coatings as K2SO4 was less reactive to the protective Cr-rich oxide. The alumina-forming NiAl exhibited a better corrosion performance under KCl, though it partially suffered from selective sulfidation when exposed to the mixed salt.

Izotermična oksidacija med elektroiskrilnim nanašanjem NiCrAlY prevleke na monokristal Ni superzlitine

Izotermična oksidacija med elektroiskrilnim nanašanjem NiCrAlY prevleke na monokristal Ni superzlitine

Mechanical, Tribological, and Oxidation Resistance Properties of NiCrAlY Coating by Atmospheric Plasma Spraying

In this paper, the NiCrAlY coating was prepared by atmospheric plasma spraying (APS) and the influence of heat treatment on the mechanical property, tribological property and oxidation resistance property of coating were researched. The coating was heat-treated at 900 oC and 1100 oC, respectively. The microstructure of coating became more homogeneous after heat treatment. Meanwhile, heat treatment could effectively increase the microhardness and adhesive strength as well as decrease the porosity of coating. The coating presented the highest adhesive strength of 62.1 MPa and the lowest porosity of 3.06 % as well as the excellent tribological property and oxidation resistance property at 900 oC after 1100 oC heat treatment.

High-Temperature Corrosion of HVAF-Sprayed Ni-Based Coatings for Boiler Applications

The present study investigates the initial corrosion behaviour of HVAF-sprayed NiCr, NiAl and NiCrAlY coatings in two different environments, O2 + H2O and O2 + H2O + KCl at 600 °C for up to 168 h in order to evaluate the possibility of utilizing such coatings in biomass- and waste-fired boilers. SEM/EDX analysis showed that all coatings displayed a protective behaviour in O2 + H2O. Upon addition of KCl (O2 + H2O + KCl), the corrosion behaviour of the NiCr coating drastically changed as it formed a thick oxide layer and displayed major chlorine diffusion down to the substrate. The NiCrAlY coating displayed a significantly better corrosion resistance with only minor oxide formation. The NiAl coating exhibited a protective behaviour similar to when exposed in the absence of KCl indicating that a thin protective oxide has formed on the coating surface. The performance of the NiAl and NiCrAlY coatings is promising for future studies with long-term exposures in more corrosive environments such as in a biomass- and waste-fired boiler.

Effect of heat treatment and synergistic rare-earth modified NiCrAlY on bonding strength of nanostructured 8YSZ coatings

In this paper, the nanostructured 8YSZ coatings and two kinds of bond coatings including NiCrAlY and NiCrAlYCe coatings were deposited by atmospheric plasma spraying onto nickel-based superalloys. The microstructure of as-sprayed coatings and the effect of heat treatment on bonding strength of NiCrAlY/8YSZ and NiCrAlYCe/8YSZ coatings were investigated by scanning electron microscopy (SEM) and transmission electron microscopy (TEM), together with energy dispersive spectrum (EDS) and X-ray diffraction (XRD) analysis. The results indicate that the coatings exhibit typical bi-modal microstructure and the grain size of 8YSZ coatings keeps nanostructure. As for 8YSZ coatings, the phase transformation occurs from t phase to t′ phase during plasma spraying and the heat treatment does not change the phase structure. The heat treatment and rare-earth modified NiCrAlY coatings play an important role in enhancing the bonding strength of as-sprayed coatings significantly compared with NiCrAlY/8YSZ coatings. The bonding strength of NiCrAlYCe/8YSZ coatings whose temperature of the heat treatment is 800 °C @ 6 h can reach 48.9 MPa, which is 1.5 times than that of as-sprayed NiCrAlYCe/8YSZ coatings.

Identification of the Anisotropic Elastic Parameters of NiCrAlY Coating by Combining Nanoindentation and Finite Element Method

For vibration damping, coatings are prepared on surface of the structures (substrates), which constitute the coating‐substrate composite structures. Elastic parameters of the coating are indispensable for the vibration and damping analysis of the composite structure. Due to the small scale of coating thickness and elastic difference compared with the substrate, the identification results are inevitably influenced by the existence of substrate. Moreover, resulting from the preparation process, elastic properties of hard coating often exhibit anisotropic properties. All the above factors bring about the difficulties of accurate identification. In this study, a method for identifying anisotropic elastic parameters of hard coatings considering substrate effect is proposed, by combining nanoindentation and finite element analysis. Based on the identification results, finite element models are established to analyze the vibration characteristics of the coating‐substrate composite structure, which verify the rationality of the anisotropic elastic parameters for vibration analysis. The studies in this paper are significant to more accurately identify the mechanical parameters for establishing the dynamic model. Moreover, they lay the foundation for further optimization design of hard coating damping.

Study of Wear on Nicraly Coating Sprayed by HVOF on 316 Steel and Laser CO<sub>2</sub> Remelting Process

The use of NiCrAlY is a great alternative as Bond Coat - BC (bonding layer) in coatings for turbine vane, and it is possible to increase its life. This work aims to study the BC layer of NiCrAlY on the substrate of 316 steel which was deposited by the High Velocity Oxygen Fuel method (HVOF) and after laser remelting irradiated.selective laser melting which is an innovative process. The laser treatment induced changes in porosity, microhardness and wear resistance. After spraying, the samples were irradiated with a CO2laser beam by varying the scan speed in 50, 100 e 200 mm/s. The speed at which the metallurgical bond between the coating and the substrate occurred was of 50 mm/s. A wear test was performed to analyze the thickness of the coating, which was 60 μm, and the hardness profile and hardness profile where it presented a higher hardness in the coating after the laser treatment. The investigations range included analysis of top surface of coatings by XRD characterization oxides formed types and microscopic investigations of coatings morphology.

Effect of water vapor on the oxidation behavior of HVAF‐sprayed NiCr and NiCrAlY coatings

Isothermal oxidation behavior of NiCr and NiCrAlY coatings deposited onto low alloy 16Mo3 steel by high‐velocity air fuel (HVAF) process was investigated in 5% O2 + 20% H2O + N2 at 600 °C for 168 h. Whereas NiCrAlY showed lower mass gain compared to NiCr, both coatings succeeded in maintaining the integrity with the substrate during the exposure without any breakaway oxidation. A thin Cr‐rich oxide scale (Cr2O3) formed on NiCr, and a thin mixed oxide scale (Al2O3 with NiCr2O4) formed on NiCrAlY significantly increasing the oxidation protection in the presence of water vapor.

Damping Properties of Arc Ion Plating NiCrAlY Coating with Vacuum Annealing

NiCrAlY coating was prepared on a stainless steel substrate by an arc ion plating machine and the annealing experiments were carried out at different temperatures using a tube furnace. The effects of annealing temperatures on the morphology, structure, chemical composition and phase structure of the coating were characterized by SEM, EDS and XRD, respectively. The change of microstructure is discussed. Dynamic mechanical analyzer results determined the suitable annealing temperature for the best damping performance. The effect of annealing temperature on the microstructure and damping properties of NiCrAlY coating are also discussed. The relationship between annealing temperature and damping properties are explained by microstrcuture, grain size and phase structure.

Thermophysical Properties of Cold- and Vacuum Plasma-Sprayed Cu-Cr-X Alloys, NiAl and NiCrAlY Coatings I: Electrical and Thermal Conductivity, Thermal Diffusivity, and Total Hemispherical Emissivity

This two-part paper reports the thermophysical properties of several cold- and vacuum plasma-sprayed monolithic Cu- and Ni-based alloy coatings. Part I presents the electrical and thermal conductivity, thermal diffusivity, and total hemispherical emissivity data, while Part II reports the specific heat capacity data for these coatings. Metallic copper alloys and stoichiometric NiAl and NiCrAlY coatings were fabricated by either the cold spray or the vacuum plasma spray deposition processes for thermal property measurements between 77 and 1223 K. The temperature dependencies of the thermal conductivities, thermal diffusivities, electrical conductivities, and total hemispherical emissivities of these cold- and vacuum-sprayed monolithic coatings are reported in this paper. The electrical and thermal conductivity data correlate reasonably well for Cu-8%Cr-1%Al, Cu-23%Cr-5%Al, and NiAl in accordance with the Wiedemann–Franz (WF) law although a better fit is obtained using the Smith–Palmer relationship. The Lorentz numbers determined from the WF law are close to the theoretical value.