Effect of Hf-Doped MCrAlY Alloy on the Structure and Properties of Thermally Grown Oxide Layer
Source abstract
Abstract
The NiCoCrAlY and NiCoCrAlYHf bond layer alloy was prepared by vacuum melting, followed by the deposition of a ZrO2-7%Y2O3 (7YSZ) ceramic coating on its surface using atmospheric plasma spraying. The cyclic oxidation process of the coating was systematically investigated through extensive analytical equipment and first-principles calculations and compared with conventional NiCoCrAlY coatings. It is demonstrated that NiCoCrAlYHf coatings exhibit greater resistance to oxidation and peeling than NiCoCrAlY coatings when thermally cycled at 1050 °C in air. The reason for this difference is that Hf doping can reduce the growth rate of the thermally grown oxide (TGO). In addition, the formation of HfO2 in the TGO layer, which delays the phase transition of Al2O3, reduces the growth of internal stresses in the coating and improves the adhesion of the TGO layer and bond strength of the interface. As a result, Hf doping significantly increases the oxidation lifetime of the coating, approximately 8 times that of NiCoCrAlY.
Source: expertdata · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: High-Temperature Coating Behaviors · Catalytic Processes in Materials Science · Advancements in Solid Oxide Fuel Cells
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (59)
Show source-provided references
1. X. Chen, Y. Zhang, X. Zhong, Z. Xu, J. Zhang, Y. Cheng, Y. Zhao, Y. Liu, X. Fan, Y. Wang, H. Ma, and X. Cao, Thermal Cycling Behaviors of the Plasma Sprayed Thermal Barrier Coatings of Hexaluminates with Magnetoplumbite Structure, J. Eur. Ceram. Soc., 2010, 30, p 1649–1657.10.1016/j.jeurceramsoc.2010.01.013 ↗
2. Z. Xu, S. He, L. He, R. Mu, G. Huang, and X. Cao, Novel Thermal Barrier Coatings Based on La2(Zr0.7Ce0.3)2O7/8YSZ Double-Ceramic-Layer Systems Deposited by Electron Beam Physical Vapor Deposition, J. Alloys Compd., 2011, 509, p 4273–4283.10.1016/j.jallcom.2010.12.203 ↗
3. D.F. Susan and A.R. Marder, Ni–Al Composite Coatings: Diffusion Analysis and Coating Lifetime Estimation, Acta Mater., 2001, 49, p 1153–1163.10.1016/S1359-6454(01)00022-2 ↗
4. A.G. Evans, D.R. Mumm, J.W. Hutchinson, G.H. Meier, and F.S. Pettit, Mechanisms Controlling the Durability of Thermal Barrier Coatings, Prog. Mater. Sci., 2001, 46, p 505–553.10.1016/S0079-6425(00)00020-7 ↗
5. B. Gleeson, Thermal Barrier Coatings for Aeroengine Applications, J. Propuls. Power, 2006, 22, p 375–383.10.2514/1.20734 ↗
6. A.G. Evans, D.R. Clarke, and C.G. Levi, The Influence of Oxides on the Performance of Advanced Gas Turbines, J. Eur. Ceram. Soc., 2008, 28, p 1405–1419.10.1016/j.jeurceramsoc.2007.12.023 ↗
7. D.R. Clarke, M. Oechsner, and N.P. Padture, Thermal-Barrier Coatings for More Efficient Gas-Turbine Engines, MRS Bull., 2012, 37, p 891–898.10.1557/mrs.2012.232 ↗
8. J.R. Nicholls, Designing Oxidation-Resistant Coatings, JOM, 2000, 1, p 52.
9. M. Seraffon, N.J. Simms, J. Sumner, and J.R. Nicholls, The Development of New Bond Coat Compositions for Thermal Barrier Coating Systems Operating under Industrial Gas Turbine Conditions, Surf. Coat. Technol., 2011, 206, p 1529–1537.10.1016/j.surfcoat.2011.06.023 ↗
10. J.R. Nicholls, N.J. Simms, W.Y. Chan, and H.E. Evans, Smart Overlay Coatings—Concept and Practice, Surf. Coat. Technol., 2002, 149, p 236–244.10.1016/S0257-8972(01)01499-2 ↗
11. P. Song, D. Naumenko, R. Vassen, L. Singheiser, and W.J. Quadakkers, Effect of Oxygen Content in NiCoCrAlY Bondcoat on the Lifetimes of EB-PVD and APS Thermal Barrier Coatings, Surf. Coat. Technol., 2013, 221, p 207–213.10.1016/j.surfcoat.2013.01.054 ↗
12. H. Ruiz-Luna, J. Porcayo-Calderon, J.M. Alvarado-Orozco, J. García-Herrera, L. Martinez-Gomez, L. Trápaga-Martínez, and J. Muñoz-Saldaña, Electrochemical Corrosion of HVOF-Sprayed NiCoCrAlY Coatings in CO2-Saturated Brine, J. Therm. Spray Technol., 2016, 25, p 1330–1343.10.1007/s11666-016-0449-x ↗
13. L. Luo, H. Zhang, Y. Chen, C. Zhao, S. Alavi, F. Guo, X. Zhao, and P. Xiao, Effects of the β Phase Size and Shape on the Oxidation Behavior of NiCoCrAlY Coating, Corros. Sci., 2018, 145, p 262–270.10.1016/j.corsci.2018.10.008 ↗
14. Y. Chen, X. Zhao, M. Bai, L. Yang, C. Li, L. Wang, J.A. Carr, and P. Xiao, A Mechanistic Understanding on Rumpling of a NiCoCrAlY Bond Coat for Thermal Barrier Coating Applications, Acta Mater., 2017, 128, p 31–42.10.1016/j.actamat.2017.02.003 ↗
15. A.G. Mora-García, H. Ruiz-Luna, M. Mosbacher, R. Popp, U. Schulz, U. Glatzel, and J. Muñoz-Saldaña, Microstructural Analysis of Ta-Containing NiCoCrAlY Bond Coats Deposited by HVOF on Different Ni-Based Superalloys, Surf. Coat. Technol., 2018, 354, p 214–225.10.1016/j.surfcoat.2018.09.025 ↗
16. D. Mercier, B.D. Gauntt, and M. Brochu, Thermal Stability and Oxidation Behavior of Nanostructured NiCoCrAlY Coatings, Surf. Coat. Technol., 2011, 205, p 4162–4168.10.1016/j.surfcoat.2011.03.005 ↗
17. C. Li, D. Li, X. Yuan, P. Song, J. Feng, T. Huang, and J. Lu, Effect of Water Vapour on Preferential Orientation of Thermally Grown Oxide at 1050 °C, Corros. Sci., 2022, 209, p 110737.10.1016/j.corsci.2022.110737 ↗
18. P. Song, M. Subanovic, J. Toscano, D. Naumenko, and W.J. Quadakkers, Effect of Atmosphere Composition on the Oxidation Behavior of MCrAlY Coatings, Mater. Corros., 2011, 62, p 699–705.10.1002/maco.201005851 ↗
19. C. Li, X. Yuan, D. Li, P. Song, Z. Li, T. Huang, J. Feng, Y. He, R. Zhai, Q. Li, C. Hua, W. Huang, D. Zhang, and J. Lu, Test Atmospheres Affecting Voids Distribution on MCrAlY-Bond Coats for TBCs at 1050 °C, Corros. Sci., 2022, 195, p 109967.10.1016/j.corsci.2021.109967 ↗
20. Z.D. Xiang and P.K. Datta, Formation of Hf- and W-Modified Aluminide Coatings on nickel–Base Superalloys by the Pack Cementation Process, Mater. Sci. Eng. A, 2003, 363, p 185–192.10.1016/S0921-5093(03)00628-2 ↗
21. S.A. Azarmehr, K. Shirvani, M. Schütze, and M. Galetz, Microstructural Evolution of Silicon-Platinum Modified Aluminide Coatings on Superalloy GTD-111, Surf. Coat. Technol., 2017, 321, p 455–463.10.1016/j.surfcoat.2017.05.019 ↗
22. F. Wang, H. Lou, L. Bai, and W. Wu, Hot Corrosion of Yttrium-Modified Aluminide Coatings, Mater. Sci. Eng. A, 1989, 120–121, p 387–389.
23. C. Li, P. Song, A. Khan, J. Feng, K. Chen, J. Zang, X. Xiong, J. Lü, and J. Lu, Influence of Water Vapour on the HfO2 Distribution within the Oxide Layer on CoNiCrAlHf Alloys, J. Alloys Compd., 2018, 739, p 690–699.10.1016/j.jallcom.2017.12.334 ↗
24. E. Pauletti and A.S.C.M. d’Oliveira, Influence of Pt Concentration on Structure of Aluminized Coatings on a Ni Base Superalloy, Surf. Coat. Technol., 2017, 332, p 57–63.10.1016/j.surfcoat.2017.10.052 ↗
25. L. Ye, H. Chen, B. Liu, G. Yang, H. Luo, and Y. Gao, Effect of Pt Content on Initial TGO Formation and Available Al Reserve of Pt-Al Coatings during Thermal Cycling, Surf. Coat. Technol., 2018, 337, p 82–89.10.1016/j.surfcoat.2018.01.002 ↗
26. T. Huang, J. Lü, P. Song, A. Khan, R. Chen, and J. Yi, Effect of Pt Doping on Oxide Scale Formation on Yttria-Dispersion FeCrAl Alloy at 1200°C, Corros. Sci., 2020, 168, p 108580.10.1016/j.corsci.2020.108580 ↗
27. P. Song, J. Lu, T. Huang, D. Zhang, and J. Lü, Different Growth Mechanisms of Alumina on the Surface of NiPtAl and MCrAlY Bondcoatings in EB-PVD TBC System, Xiyou Jinshu Cailiao Yu Gongcheng/Rare Met. Mater. Eng., 2014, 43, p 601–604.
28. N. An, Q. Yu, G. Liu, S. Li, M. Jia, and W. Zhang, Complete Oxidation of Formaldehyde at Ambient Temperature Over Supported Pt/Fe2O3 Catalysts Prepared by Colloid-Deposition Method, J. Hazard. Mater., 2011, 186, p 1392–1397.10.1016/j.jhazmat.2010.12.018 ↗
29. B.A. Pint, J.A. Haynes, Y. Zhang, K.L. More, and I.G. Wright, The Effect of Water Vapor on the Oxidation Behavior of Ni–Pt–Al Coatings and Alloys, Surf. Coat. Technol., 2006, 201, p 3852–3856.10.1016/j.surfcoat.2006.07.244 ↗
30. B.A. Pint, Optimization of Reactive-Element Additions to Improve Oxidation Performance of Alumina-Forming Alloys, J. Am. Ceram. Soc., 2003, 86, p 686–695.10.1111/j.1151-2916.2003.tb03358.x ↗
31. T.F. An, H.R. Guan, X.F. Sun, and Z.Q. Hu, Effect of the θ–α-Al2O3 Transformation in Scales on the Oxidation Behavior of a Nickel-Base Superalloy with an Aluminide Diffusion Coating, Oxid. Met., 2000, 54, p 301–316.10.1023/A:1004654429687 ↗
32. M.W. Brumm and H.J. Grabke, The Oxidation Behaviour of NiAl-I. Phase Transformations in the Alumina Scale during Oxidation of NiAl and NiAl-Cr Alloy, Corros. Sci., 1992, 33, p 1677–1690.10.1016/0010-938X(92)90002-K ↗
33. C. Mennicke, D.R. Mumm, and D.R. Clarke, Transient Phase Evolution during Oxidation of a Two-Phase NiCoCrAlY Bond Coat, Z. Met., 1999, 90, p 1079–1084.
34. N.B. Dahotre, J.M. Hampikian, and J.E. Morral, Elevated Temperature Coatings, Science and Technology IV (1999).
35. P. John, Perdew, Kieron, Burke, Matthias, Ernzerhof, Erratum, Generalized Gradient Approximation Made Simple, Phys. Rev. Lett., 1996, 77, p 3865–3868.10.1103/PhysRevLett.77.3865 ↗
36. M.D. Segall, P.J.D. Lindan, M.J. Probert, C.J. Pickard, P.J. Hasnip, S.J. Clark, and M.C. Payne, First-Principles Simulation: Ideas, Illustrations and the CASTEP Code, J. Phys. Condens. Matter, 2002, 14, p 2717–2744.10.1088/0953-8984/14/11/301 ↗
37. H.J. Grabke, M.W. Brumm, and B. Wagemann, The Oxidation of NiAl and FeAl, Oxidation of Intermetallics (2004).
38. D. Texier, D. Monceau, F. Crabos, and E. Andrieu, Tensile Properties of a Non-line-of-sight Processed β-γ-γ′ MCrAlY Coating at High Temperature, Surf. Coat. Technol., 2017, 326, p 28–36.10.1016/j.surfcoat.2017.07.026 ↗
39. G.C. Wood and F.H. Stott, Oxidation of Alloys, Mater. Sci. Technol., 1987, 3, p 519–530.10.1080/02670836.1987.11782263 ↗
40. P.Y. Hou, T. Izumi, and B. Gleeson, Sulfur Segregation at Al2O3/γ-Νi + γ′-Ni3Al Interfaces: Effects of Pt, Cr and Hf Additions, Oxid. Met., 2009, 72, p 109–124.10.1007/s11085-009-9149-y ↗
41. K.M. Carling and E.A. Carter, Effects of Segregating Elements on the Adhesive Strength and Structure of the α-Al2O3/β-NiAl Interface, Acta Mater., 2007, 55, p 2791–2803.10.1016/j.actamat.2006.12.020 ↗
42. I. Levin and D. Brandon, Metastable Alumina Polymorphs: Crystal Structures and Transition Sequences, J. Am. Ceram. Soc., 1998, 81, p 1995–2012.10.1111/j.1151-2916.1998.tb02581.x ↗
43. A. Dauger and D. Fargeot, T.E.M. Study of Al2O3 Metastable Phases, Radiat. Eff., 1983, 74, p 279–289.10.1080/00337578308218421 ↗
44. B.A. Pint, J.R. Martin, and L.W. Hobbs, The Oxidation Mechanism of θ-Al2O3 Scales, Solid State Ionics, 1995, 78, p 99–107.10.1016/0167-2738(95)00013-V ↗
45. M. Ozawa, M. Kimura, and A. Isogai, Thermal Stability and Characterization of γ-Al2O3 Modified with Rare Earths, J. Less Common Met., 1990, 162, p 297–308.10.1016/0022-5088(90)90345-K ↗
46. B.A. Pint, M. Treska, and L.W. Hobbs, The Effect of Various Oxide Dispersions on the Phase Composition and Morphology of Al2O3 Scales Grown on β-NiAl, Oxid. Met., 1997, 47, p 1–20.10.1007/BF01682369 ↗
47. A.B. Pint, Limitations on the Use of Ion Implantation for the Study of the Reactive Element Effect in β-NiAl, J. Electrochem. Soc., 1994, 141, p 2443–2452.10.1149/1.2055140 ↗
48. P. Burtin, J.P. Brunelle, M. Pijolat, and M. Soustelle, Influence of Surface Area and Additives on the Thermal Stability of Transition Alumina Catalyst Supports. I: Kinetic Data, Appl. Catal., 1987, 34, p 225–238.10.1016/S0166-9834(00)82458-6 ↗
49. G.M. Ecer and G.H. Meier, The Effect of Cerium on the Oxidation of Ni-50Cr Alloys, Oxid. Met., 1979, 13, p 159–180.10.1007/BF00611977 ↗
50. P.Y. Hou, A.P. Paulikas, and B.W. Veal, Stress Development and Relaxation in Al2O3 during Early Stage Oxidation of β-NiAl, Mater. High Temp., 2005, 22, p 535–543.10.3184/096034005782744146 ↗
51. M. Martena, D. Botto, P. Fino, S. Sabbadini, M.M. Gola, and C. Badini, Modelling of TBC System Failure: Stress Distribution as a Function of TGO Thickness and Thermal Expansion Mismatch, Eng. Fail. Anal., 2006, 13, p 409–426.10.1016/j.engfailanal.2004.12.027 ↗
52. D.H. Park, H.J. Jang, Y.G. Jung, J.C. Chang, and U. Paik, Analysis of Residual Stress and Damage Durability with Thermal Fatigue Behavior in Thermal Barrier Coatings, MRS Proc., 2004, 821, p 264–269.
53. D.P. Whittle and J. Stringer, Improvement in Properties: Additives in Oxidation Resistance, Philos. Trans. R. Soc. Lond. Ser. A, 1980, 295, p 309–329.10.1098/rsta.1980.0124 ↗
54. A.G. Evans, M.Y. He, and J.W. Hutchinson, Mechanics-Based Scaling Laws for the Durability of Thermal Barrier Coatings, Prog. Mater. Sci., 2001, 46, p 249–271.10.1016/S0079-6425(00)00007-4 ↗
55. D.P. Whittle and J. Stringer, Improvements in High Temperature Oxidation Resistance by Additions of Reactive Elements or Oxide Dispersions, Philos. Trans. R. Soc. A Math. Phys. Eng. Sci., 1980, 295, p 309–329.
56. I.M. Allam, D.P. Whittle, and J. Stringer, The Oxidation Behavior of CoCrAI Systems Containing Active Element Additions, Oxid. Met., 1978, 12, p 35–66.10.1007/BF00609974 ↗
57. J.E. Antill and K.A. Peakall, Influence of an Alloy Addition of Y on the Oxidation Behaviour of an Austenitic and a Ferritic Stainless Steel in Carbon Dioxide, J. Iron Steel Inst. (Lond.), 1967, 205, p 1136–1142.
58. T. Zumkley, M.P. Macht, V. Naundorf, J. Rusing, and G. Frohberg, Impurity Diffusion in ZrTiCuNiBe Bulk Metallic Glasses, J. Metastab. Nanocryst. Mater., 2000, 8, p 135–139.
59. S. Bokstein, S.Z. Bokstein, and I.T. Spitsberg, Self-diffusion of Ni in Ni3Al Intermetallic Compound Alloyed with Cr, Mo, Hf, Ta, and B, Deformation and Fracture of Ordered Intermetallic Materials III (1996), pp. 285–302.10.1016/0966-9795(96)00038-6 ↗