journal article·2025-09-29Open access

PVD Ce-coating to mitigate intergranular oxidation of additively manufactured Ni-base alloy IN625

A. Chyrkin, A. Fazi, M. Sattari, M. Thuvander, K. Stiller, M. Halvarsson, E. Wessel, D. Naumenko, J. Froitzheim

npj Materials Degradation· Volume 9· Issue 1

Abstract

Abstract Additively manufactured Ni-base alloy IN625 suffered from intergranular oxidation (IGO) during air exposure at 900 °C. IGO is triggered by oxide buckling over the alloy’s grain boundaries (GBs), followed by oxidation of the open intergranular voids. Application of a 10 nm thick PVD coating of Ce induced a slower inward growth of the Cr2O3 scale, better oxide adherence and as a result strongly suppressed IGO. The main beneficial effect provided by Ce is improved oxide adherence preventing oxide buckling and oxidation of intergranular voids.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: Additive Manufacturing Materials and Processes · High-Temperature Coating Behaviors · Advanced materials and composites

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (78)

Show source-provided references
1. Reed, R. C. The Superalloys. https://doi.org/10.1017/CBO9780511541285 (Cambridge University Press, 2006).10.1017/CBO9780511541285 ↗
2. Murr, L. E. Metallurgy of additive manufacturing: examples from electron beam melting. Addit. Manuf. 5, 40–53 (2015).
3. Frazier, W. E. Metal additive manufacturing: a review. J. Mater. Eng. Perform. 23, 1917–1928 (2014).10.1007/s11665-014-0958-z ↗
4. DebRoy, T. et al. Additive manufacturing of metallic components—process, structure and properties. Prog. Mater. Sci. 92, 112–224 (2018).10.1016/j.pmatsci.2017.10.001 ↗
5. Karmuhilan, M. & Kumanan, S. A review on additive manufacturing processes of Inconel 625. J. Mater. Eng. Perform. 31, 2583–2592 (2022).10.1007/s11665-021-06427-3 ↗
6. Sanchez, S. et al. The creep behaviour of nickel alloy 718 manufactured by laser powder bed fusion. Mater. Des. 204, 109647 (2021).10.1016/j.matdes.2021.109647 ↗
7. Kassner, M. E., Son, K. T., Lee, K. A., Kang, T.-H. & Ermagan, R. The creep and fracture behavior of additively manufactured Inconel 625 and 718. Mater. High. Temp. 39, 499–506 (2022).10.1080/09603409.2022.2045101 ↗
8. Son, K., Kassner, M. E. & Lee, K. A. The creep behavior of additively manufactured Inconel 625. Adv. Eng. Mater. 22, 1900543 (2020).10.1002/adem.201900543 ↗
9. Son, K.-T. et al. The creep and fracture properties of additively manufactured Inconel 625. Materialia 15, 101021 (2021).10.1016/j.mtla.2021.101021 ↗
10. de Leon Nope, G., Wang, G., Alvarado-Orozco, J. M. & Gleeson, B. Role of elemental segregation on the oxidation behavior of additively manufactured alloy 625. JOM 74, 1698–1706 (2022).10.1007/s11837-022-05200-8 ↗
11. de Leon Nope, G., Wang, G., Alvarado-Orozco, J. M. & Gleeson, B. Effects of High-temperature oxidation on fatigue life of additive-manufactured alloy 625. Miner., Met. Mater. Ser. 249, 269 (2023).
12. de Leon Nope, G., Wang, G. & Gleeson, B. Influence of alloy 625 manufacturing process on 950 °C oxidation behavior in air and post-oxidation high-cycle fatigue performance. High. Temp. Corros. Mater. 1, 13 (2024).
13. Chyrkin, A. et al. High-temperature oxidation behavior of additively manufactured IN625: Effect of microstructure and grain size. Corros. Sci. 205, 110382 (2022).10.1016/j.corsci.2022.110382 ↗
14. Chyrkin, A. et al. Intergranular oxidation of additively manufactured Ni-base alloy 625: the role of Si. Corros. Sci. 219, 111234 (2023).10.1016/j.corsci.2023.111234 ↗
15. Parizia, S. et al. Effect of heat treatment on microstructure and oxidation properties of Inconel 625 processed by LPBF. J. Alloy. Compd. 846, 156418 (2020).10.1016/j.jallcom.2020.156418 ↗
16. Ramenatte, N. et al. A comparison of the high-temperature oxidation behaviour of conventional wrought and laser beam melted Inconel 625. Corros. Sci. 164, 108347 (2020).10.1016/j.corsci.2019.108347 ↗
17. Pineda-Arriaga, K. Y. et al. Oxidation in water vapor of Inconel 625 fabricated by additive manufacturing. High. Temp. Corros. Mater. 101, 1–11 (2024).10.1007/s11085-023-10205-y ↗
18. Pineda-Arriaga, K. Y. et al. Characterization of the high-temperature oxidation behavior of Inconel 625® fabricated by additive manufacturing and conventional methods. Oxid. Met. 98, 489–510 (2022).10.1007/s11085-022-10136-0 ↗
19. Condruz, M. R., Matache, G., Paraschiv, A., Badea, T. & Badilita, V. High temperature oxidation behavior of selective laser melting manufactured IN625. Metals 10, 668 (2020).10.3390/met10050668 ↗
20. Sharifitabar, M., Khorshahian, S., Shafiee Afarani, M., Kumar, P. & Jain, N. K. High-temperature oxidation performance of Inconel 625 superalloy fabricated by wire arc additive manufacturing. Corros. Sci. 197, 110087 (2022).10.1016/j.corsci.2022.110087 ↗
21. Lewis, E. R. et al. Microstructural characterisation and high-temperature oxidation of laser powder bed fusion processed Inconel 625. Mater. Lett. 311, 131582 (2022).10.1016/j.matlet.2021.131582 ↗
22. Andrade, B. W., Mariani, F. E., Coelho, R. T. & de Sousa Malafaia, A. M. Comparison of the oxidation behavior at high temperature of INCONEL 625 forged and produced by additive manufacturing. High. Temp. Corros. Mater. 1, 14 (2024).
23. Sanviemvongsak, T., Monceau, D., Desgranges, C. & Macquaire, B. Intergranular oxidation of Ni-base alloy 718 with a focus on additive manufacturing. Corros. Sci. 170, 108684 (2020).10.1016/j.corsci.2020.108684 ↗
24. Sanviemvongsak, T., Monceau, D. & Macquaire, B. High temperature oxidation of IN 718 manufactured by laser beam melting and electron beam melting: effect of surface topography. Corros. Sci. 141, 127–145 (2018).10.1016/j.corsci.2018.07.005 ↗
25. Sanviemvongsak, T. et al. Cyclic oxidation of alloy 718 produced by additive manufacturing compared to a wrought-718 alloy. Corros. Sci. 192, 109804 (2021).10.1016/j.corsci.2021.109804 ↗
26. Calandri, M. et al. Solution treatment study of Inconel 718 produced by SLM additive technique in view of the oxidation resistance. Adv. Eng. Mater. 20, 1800351 (2018).10.1002/adem.201800351 ↗
27. Kunze, K., Etter, T., Grässlin, J. & Shklover, V. Texture, anisotropy in microstructure and mechanical properties of IN738LC alloy processed by selective laser melting (SLM). Mater. Sci. Eng.: A 620, 213–222 (2015).10.1016/j.msea.2014.10.003 ↗
28. Rezaei, A. et al. Microstructural and mechanical anisotropy of selective laser melted IN718 superalloy at room and high temperatures using small punch test. Mater. Charact. 162, 110200 (2020).10.1016/j.matchar.2020.110200 ↗
29. Pleass, C. & Jothi, S. Influence of powder characteristics and additive manufacturing process parameters on the microstructure and mechanical behaviour of Inconel 625 fabricated by Selective Laser Melting. Addit. Manuf. 24, 419–431 (2018).
30. Chyrkin, A. et al. Oxidation of additively manufactured Ni-base alloy IN625: mechanism of intergranular oxidation. Corros. Sci. 256, 113218 (2025).10.1016/j.corsci.2025.113218 ↗
31. Whittle, D. P. & Stringer, J. Improvements in high temperature oxidation resistance by additions of reactive elements or oxide dispersions. Philos. Trans. R. Soc. Lond. Ser. A Math. Phys. Sci. 295, 309–329 (1980).
32. Hou, P. Y. & Stringer, J. The effect of reactive element additions on the selective oxidation, growth and adhesion of chromia scales. Mater. Sci. Eng. A 202, 1–10 (1995).10.1016/0921-5093(95)09798-8 ↗
33. Pint, B. A. Progress in understanding the reactive element effect since the Whittle and Stringer literature review. John Stringer Symp. High. Temp. Corros. 9, 19 (2001).
34. Quadakkers, J. & Singheiser, L. Practical aspects of the reactive element effect. Mater. Sci. Forum 369–372, 77–92 (2001).10.4028/www.scientific.net/MSF.369-372.77 ↗
35. Chyrkin, A., Huczkowski, P., Shemet, V., Singheiser, L. & Quadakkers, W. J. Sub-scale depletion and enrichment processes during high temperature oxidation of the nickel base alloy 625 in the temperature range 900–1000 °C. Oxid. Met. 75, 143–166 (2011).10.1007/s11085-010-9225-3 ↗
36. Huczkowski, P. et al. Effect of gas flow rate on oxidation behaviour of alloy 625 in wet air in the temperature range 900–1000 °C. Mater. Corros. 68, 159–170 (2017).10.1002/maco.201608831 ↗
37. Chyrkin, A. et al. Modelling compositional changes in nickel base alloy 602 CA during high temperature oxidation. Mater. High Temp. 32, 102–112 (2015).10.1179/0960340914Z.00000000082 ↗
38. Vayyala, A. et al. A nanoscale study of thermally grown chromia on high-Cr ferritic steels and associated oxidation mechanisms. J. Electrochem. Soc. 167, 061502 (2020).10.1149/1945-7111/ab7d2e ↗
39. Naumenko, D., Gleeson, B., Wessel, E., Singheiser, L. & Quadakkers, W. J. Correlation between the microstructure, growth mechanism, and growth kinetics of alumina scales on a FeCrAlY alloy. Met. Mater. Trans. A Phys. Met. Mater. Sci. 38 A, 2974–2983 (2007).10.1007/s11661-007-9342-z ↗
40. Caplan, D., Harvey, A. & Cohen, M. Oxidation of chromium at 890°–1200°C. Corros. Sci. 3, 161–IN8 (1963).10.1016/S0010-938X(63)80086-4 ↗
41. Dryepondt, S., Kirka, M. M. & List III, F. A. Oxidation Behavior of Ni-Based Alloys Fabricated by Additive Manufacturing. In CORROSION 2019, pp. 1–11, Paper No. C2019–13558 (2019).10.5006/C2019-13558 ↗
42. Romedenne, M., Pillai, R., Kirka, M. & Dryepondt, S. High temperature air oxidation behavior of Hastelloy X processed by Electron Beam Melting (EBM) and Selective Laser Melting (SLM). Corros. Sci. 171, 108647 (2020).10.1016/j.corsci.2020.108647 ↗
43. Romedenne, M., Stack, P., Pillai, R. & Dryepondt, S. Isothermal and Cyclic Oxidation of Haynes 282 Processed by Electron Beam Melting (EBM) and Laser Powder Bed Fusion (LPBF) in Dry Air at 800 and >950 °C. JOM 74, 1–12 (2022).10.1007/s11837-022-05201-7 ↗
44. Yamaura, S., Igarashi, Y., Tsurekawa, S. & Watanabe, T. Structure-dependent intergranular oxidation in Ni–Fe polycrystalline alloy. Acta Mater. 47, 1163–1174 (1999).10.1016/S1359-6454(99)00007-5 ↗
45. Trindade, V. B., Krupp, U., Wagenhuber, P. E., Virkar, Y. M. & Christ, H.-J. Studying the role of the alloy-grain-boundary character during oxidation of Ni-base alloys by means of the electron back-scattered diffraction technique. Mater. High. Temp. 22, 207–212 (2005).10.3184/096034005782744029 ↗
46. Balogh, Z. & Schmitz, G. Diffusion in metals and alloys. Phys. Metall.: Fifth Ed. 1, 387–559 (2014).10.1016/B978-0-444-53770-6.00005-8 ↗
47. Desgranges, C., Lequien, F., Aublant, E., Nastar, M. & Monceau, D. Depletion and voids formation in the substrate during high temperature oxidation of Ni-Cr alloys. Oxid. Met. 79, 93–105 (2013).10.1007/s11085-012-9328-0 ↗
48. Rhines, F. N. & Wolf, J. S. The role of oxide microstructure and growth stresses in the high-temperature scaling of nickel. Met Trans. 1, 1701–1710 (1970).10.1007/BF02642020 ↗
49. Evans, H. E. Stress effects in high temperature oxidation of metals. Int. Mater. Rev. 40, 1–40 (1995).10.1179/imr.1995.40.1.1 ↗
50. Wei, F. I. & Stott, F. H. The development of Cr2O3 scales on iron-chromium alloys containing reactive elements. Corros. Sci. 29, 839–861 (1989).10.1016/0010-938X(89)90057-7 ↗
51. Hou, P. Y. & Stringer, J. The effect of aluminum as an alloying addition or as an implant on the high-temperature oxidation of Ni-25Cr. Oxid. Met. 34, 299–321 (1990).10.1007/BF00665020 ↗
52. Yaedu, A. E. et al. Understanding preferential intergranular oxidation in alloy X-750 in 480 °C CO-CO2 environments at the nanoscale. Corros. Sci. 240, 112496 (2024).10.1016/j.corsci.2024.112496 ↗
53. Madhusudan, S. et al. High Temperature Intergranular Oxidation of Nickel Based Superalloy Inconel 718. High. Temp. Corros. Mater. 101, 873–884 (2024).10.1007/s11085-024-10260-z ↗
54. Weiser, M., Olszta, M. J., Engelhard, M. H., Zhu, Z. & Schreiber, D. K. Visualizing oxygen transport pathways during intergranular oxidation in Ni-Cr. npj Mater. Degrad. 7, 1–11 (2023).10.1038/s41529-023-00387-w ↗
55. Kruska, K., Olszta, M. J., Wang, J. & Schreiber, D. K. Intergranular corrosion of Ni-30Cr in high-temperature hydrogenated water after removing surface passivating film. npj Mater. Degrad. 8, 1–10 (2024).10.1038/s41529-024-00442-0 ↗
56. Chyrkin, A., Cossu, C., Svensson, J.-E. & Froitzheim, J. Internal oxidation of a Fe–Cr binary alloy at 700–900 °C: the role of hydrogen and water vapor. Oxid. Met. 98, 273–289 (2022).10.1007/s11085-022-10121-7 ↗
57. Pfeil, L. B. Improvement in heat-resisting alloys, UK Patent, No. 459848 (1937).
58. Hou, P. Y. The reactive element effect—past, present and future. Mater. Sci. Forum 696, 39–44 (2011).10.4028/www.scientific.net/MSF.696.39 ↗
59. Chevalier, S. What did we learn on the reactive element effect in chromia scale since Pfeil’s patent?. Mater. Corros. 65, 109–115 (2014).10.1002/maco.201307310 ↗
60. Naumenko, D., Pint, B. A. & Quadakkers, W. J. Current Thoughts on reactive element effects in alumina-forming systems: in memory of John Stringer. Oxid. Met. 86, 1–43 (2016).10.1007/s11085-016-9625-0 ↗
61. Ecer, G. M. & Meier, G. H. The effect of cerium on the oxidation of Ni-50Cr alloys. Oxid. Met. 13, 159–180 (1979).10.1007/BF00611977 ↗
62. Nagini, M. & Murty, B. S. Mechanical alloying: an advanced processing route for development of iron-based oxide-dispersion-strengthened alloys. Adv. Eng. Mater. 27, 2401111 (2025).10.1002/adem.202401111 ↗
63. Falk-Windisch, H., Claquesin, J., Sattari, M., Svensson, J. E. & Froitzheim, J. Co- and Ce/Co-coated ferritic stainless steel as interconnect material for intermediate temperature solid oxide fuel cells. J. Power Sources 343, 1–10 (2017).10.1016/j.jpowsour.2017.01.045 ↗
64. Sattari, M., Sachitanand, R., Froitzheim, J., Svensson, J. E. & Jonsson, T. The effect of Ce on the high temperature oxidation properties of a Fe–22%Cr steel: microstructural investigation and EELS analysis. Mater. High. Temp. 32, 118–122 (2015).10.1179/0960340914Z.00000000084 ↗
65. Quadakkers, W. J., Holzbrecher, H., Briefs, K. G. & Beske, H. Differences in growth mechanisms of oxide scales formed on ODS and conventional wrought alloys. Oxid. Met. 32, 67–88 (1989).10.1007/BF00665269 ↗
66. Li, M., Qian, Y., Li, Y. & Zhou, Y. Beneficial effects of Ce implantation into preformed Cr2O3 scales on the subsequent oxidation of Ni-20Cr alloy. Oxid. Met. 61, 529–544 (2004).10.1023/B:OXID.0000032337.10560.b8 ↗
67. Chyrkin, A., Froitzheim, J., Zurek, J. & Naumenko, D. Austenitization triggering breakaway oxidation of FeCr-base alloys at 900. C. Corros. Sci. 244, 112605 (2025).10.1016/j.corsci.2024.112605 ↗
68. Reddy, Chausson, M. J., Svensson, T. E. & Froitzheim, J. E. J. 11–23% Cr steels for solid oxide fuel cell interconnect applications at 800 °C—how the coating determines oxidation kinetics. Int J. Hydrog. Energy 48, 12893–12904 (2023).10.1016/j.ijhydene.2022.11.326 ↗
69. Vayyala, A. et al. Effect of gas composition on the oxide scale growth mechanisms in a ferritic steel for solid oxide cell interconnects. Corros. Sci. 221, 111317 (2023).10.1016/j.corsci.2023.111317 ↗
70. Wilms, M. B., Rittinghaus, S. K., Goßling, M. & Gökce, B. Additive manufacturing of oxide-dispersion strengthened alloys: materials, synthesis and manufacturing. Prog. Mater. Sci. 133, 101049 (2023).10.1016/j.pmatsci.2022.101049 ↗
71. Quadakkers, W. J. Growth mechanisms of oxide scales on ODS alloys in the temperature range 1000–1100°C. Mater. Corros. 41, 659–668 (1990).10.1002/maco.19900411204 ↗
72. Wasilkowska, A., Bartsch, M., Messerschmidt, U., Herzog, R. & Czyrska-Filemonowicz, A. Creep mechanisms of ferritic oxide dispersion strengthened alloys. J. Mater. Process Technol. 133, 218–224 (2003).10.1016/S0924-0136(02)00237-6 ↗
73. Rakhmonov, J. U., Kenel, C., De Luca, A., Leinenbach, C. & Dunand, D. C. Effect of Y2O3 dispersoids on microstructure and creep properties of Hastelloy X processed by laser powder-bed fusion. Addit. Manuf. Lett. 3, 100069 (2022).10.1016/j.addlet.2022.100069 ↗
74. Luu, D. N., Zhou, W. & Nai, S. M. L. Influence of nano-Y2O3 addition on the mechanical properties of selective laser melted Inconel 718. Mater. Sci. Eng.: A 845, 143233 (2022).10.1016/j.msea.2022.143233 ↗
75. Hoffman, A. K. et al. Oxidation resistance in 1200°C steam of a FeCrAl alloy fabricated by three metallurgical processes. JOM 74, 1690–1697 (2022).10.1007/s11837-022-05209-z ↗
76. Fedorova, I. et al. Oxidation behavior of additively manufactured Ti-added FeCrAl alloys. High. Temp. Corros. Mater. 101, 1155–1165 (2024).10.1007/s11085-024-10276-5 ↗
77. Gunduz, K. O. et al. The effect of additive manufacturing on the initial High temperature oxidation properties of RE-containing FeCrAl alloys. Corros. Sci. 188, 109553 (2021).10.1016/j.corsci.2021.109553 ↗
78. Thompson, K. et al. In situ site-specific specimen preparation for atom probe tomography. Ultramicroscopy 107, 131–139 (2007).10.1016/j.ultramic.2006.06.008 ↗