Elemental diffusion and microarea evolution of YSZ/NiCoCrAlYHf coated single crystal superalloy after thermal exposure
Source abstract
Abstract
The interaction between the bond coat (BC) and superalloy substrate under thermal conditions is a significant factor contributing to the failure of thermal barrier coating (TBC) systems. In this paper, specimens of Yttria-stabilized zirconia (YSZ)/NiCoCrAlYHf coated single crystal superalloy DD6 were thermally exposed at 1050 °C for up to 300 h, and the evolution of the interface area was investigated through the analysis of composition-microstructure-induced performance changes. Microstructural characterization shows the initial γ+γ′ IDZ transforming into a single γ structure and extending into the substrate, which is related to the elemental diffusion. Characteristics of microstructure were further quantified using image recognition and labeling based on Cellpose algorithm. The results visually demonstrate the coarsening of γ′ in the BC/substrate interface area. Diffusion kinetics calculations indicated that the BC and the adjoining areas exhibited higher diffusivity. By combining creep performance metrics and physical models of creep, the creep resistance degradation in the interface region were explained. Ultimately, a mechanism of the performance degradation in the interface region due to elemental diffusion and microstructural evolution was proposed.
Source: openalex_inverted_index · Quality: baseline
Research context
OpenAlex topics: High-Temperature Coating Behaviors · High Entropy Alloys Studies · Intermetallics and Advanced Alloy Properties
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (54)
Show source-provided references
1. Nickel-based superalloys for advanced turbine engines: chemistry, microstructure and properties10.2514/1.18239 ↗
2. Reed · 2006
3. PVD TBC experience on GE aircraft engines10.1007/s11666-997-0012-x ↗
4. Jones · 1996 · 194
5. Thermal barrier coatings for gas-turbine engine applications10.1126/science.1068609 ↗
6. Oxidation-induced failure of EB-PVD thermal barrier coatings10.1016/S0257-8972(01)01482-7 ↗
7. Overview on advanced thermal barrier coatings10.1016/j.surfcoat.2010.08.151 ↗
8. Thermal shock and cycling behavior of thermal barrier coatings (TBCs) used in gas turbines
9. Thermal barrier coatings for aeroengine applications10.2514/1.20734 ↗
10. Thermomechanical simulations of the transient coupled effect of thermal cycling and oxidation on residual stresses in thermal barrier coatings10.1016/j.ceramint.2021.10.087 ↗
11. Chemo-thermo-mechanical modeling of EB-PVD TBC failure subjected to isothermal and cyclic thermal exposures10.1016/j.ijfatigue.2020.105817 ↗
12. Influences of MCrAlY coatings on oxidation resistance of single crystal superalloy DD98M and their inter-diffusion behaviors10.1016/j.jallcom.2015.07.095 ↗
13. Microstructure and composition evolution of a single-crystal superalloy caused by elements interdiffusion with an overlay NiCrAlY coating on oxidation10.1016/j.jmst.2019.11.017 ↗
14. On the mechanism of secondary reaction zone formation in a coated nickel-based single-crystal superalloy containing ruthenium10.1016/j.scriptamat.2013.03.015 ↗
15. Interdiffusion in MCrAlY coated nickel-base superalloys10.1016/j.surfcoat.2016.09.049 ↗
16. Precipitation phases in the nickel-based superalloy DZ 125 with YSZ/CoCrAlY thermal barrier coating10.1016/j.jallcom.2011.05.102 ↗
17. Compositional effects on the high-temperature oxidation lifetime of MCrAlY type coating alloys10.1016/j.corsci.2015.03.011 ↗
18. Effect of temperature gradient on microstructure evolution in ni–al–cr bond coat/substrate systems: a phase-field study10.1016/j.surfcoat.2014.10.061 ↗
19. Interdiffusion behavior between NiAlHf coating and Ni-based single crystal superalloy with different crystal orientations10.1016/j.apsusc.2014.11.101 ↗
20. Microstructure evolution of an EB-PVD NiAl coating and its underlying single crystal superalloy substrate10.1016/j.jallcom.2016.02.115 ↗
21. Effect of alloying elements in Ni-base substrate material on interdiffusion processes in MCrAlY-coated systems10.1016/j.surfcoat.2018.07.020 ↗
22. Predicting effect of base alloy composition on Oxidation- and interdiffusion-induced degradation of an MCrAlY coating10.1007/s11837-018-2950-9 ↗
23. Microstructure evolution and interdiffusion behaviors of (Ni,Pt)Al coating with and without Re-diffusion barrier on IC21 substrate at 1100°C10.1016/j.matchar.2021.111450 ↗
24. Microstructural evolution of NiCoCrAlY coated directionally solidified superalloy10.1016/j.surfcoat.2022.128487 ↗
25. Temperature-dependent evolution mechanism of interface microstructure between gradient MCrAlY coatings and nickel-based superalloy10.1016/j.matdes.2023.112585 ↗
26. Comparative study on the initial oxidation behavior of conventional and nanocrystalline MCrAlY coatings - effect of microstructure evolution and dynamic mechanisms10.1016/j.actamat.2022.118264 ↗
27. A combinatorial approach for structural materials10.1002/1527-2648(200103)3:3<143::AID-ADEM143>3.0.CO;2-F ↗
28. Discovery of new materials and heat treatments: accelerated metallurgy and the case of ferrous and magnesium alloys10.4028/www.scientific.net/MSF.783-786.2188 ↗
29. High-throughput characterization methods for Ni-based superalloys and phase prediction via deep learning10.1016/j.jmrt.2022.10.032 ↗
30. High-throughput solid solution strengthening characterization in high entropy alloys10.1016/j.actamat.2019.01.029 ↗
31. High-Throughput method–accelerated design of Ni-Based superalloys
32. Phase prediction of Ni-base superalloys via high-throughput experiments and machine learning10.1080/21663831.2020.1815093 ↗
33. High throughput experiment assisted discovery of new Ni-base superalloys10.1016/j.scriptamat.2019.11.019 ↗
34. SAMM: a general-purpose segmentation model for material micrographs based on the segment anything model 2
35. Cellpose: a generalist algorithm for cellular segmentation10.1038/s41592-020-01018-x ↗
36. PANDAT software with PanEngine, PanOptimizer and PanPrecipitation for multi-component phase diagram calculation and materials property simulation10.1016/j.calphad.2008.08.004 ↗
37. Effect of Ta on microstructural evolution of NiCrAlYSi coated Ni-base single crystal superalloys10.1016/j.jallcom.2020.154440 ↗
38. Effect of thermal exposure on stress distribution in TGO layer of EB-PVD TBC10.1016/S1359-6454(03)00046-6 ↗
39. Substrate depletion analysis and modeling of the high temperature oxidation of binary alloys10.1007/s11085-012-9353-z ↗
40. Stringer
41. Cross terms in the thermodynamic diffusion equations for multicomponent alloys10.1007/BF02811561 ↗
42. A pragmatic method to determine the composition-dependent interdiffusivities in ternary systems by using a single diffusion couple10.1016/j.scriptamat.2014.07.016 ↗
43. High-throughput determination of interdiffusivity matrices in Ni-Al-Ti-Cr-Co-Mo-Ta-W multicomponent superalloys and their application in optimization of creep resistance
44. Viscosity and diffusivity in melts: from unary to multicomponent systems10.1080/14786435.2014.890755 ↗
45. On the prediction of the yield stress of unimodal and multimodal γ′ nickel-base superalloys10.1016/j.actamat.2015.07.048 ↗
46. Strengthening mechanisms in polycrystalline multimodal nickel-base superalloys10.1007/s11661-009-9858-5 ↗
47. Diffusion in solids, 2
48. Interdiffusion mechanism between EB-PVD deposited CoCrAlY bond-coat and superalloy substrate under high-temperature oxidation service conditions in gas turbine10.1016/j.corsci.2024.112463 ↗
49. Microstructure evolution and interdiffusion of PtAl coated a third generation single crystal superalloy during thermal exposure10.1016/j.vacuum.2022.111225 ↗
50. Element accumulation beneath the scale/alloy interface of a CoNiCrAlReY alloy10.1016/j.corsci.2014.09.015 ↗
51. Analysis of pore formation at oxide–alloy Interfaces—Ii: Theoretical treatment of vacancy condensation for immobile interfaces10.1023/A:1023065915321 ↗
52. Isolation and testing of new single crystal superalloys using alloys-by-design method10.1016/j.msea.2016.04.089 ↗
53. Alloys-by-design: towards optimization of compositions of nickel-based superalloys
54. A model for the creep deformation behaviour of nickel-based single crystal superalloys10.1016/j.actamat.2012.05.023 ↗