Studies on thermally grown oxide as an interface between plasma-sprayed coatings and a nickel-based superalloy substrate

Adam Khan Mahaboob Basha; Sundarrajan Srinivasan; Natarajan Srinivasan

doi:10.1007/s12613-017-1451-0

Volume 24 Issue 6

Jun. 2017

Turn off MathJax

Article Contents

Article Navigation > International Journal of Minerals, Metallurgy and Materials > 2017 > 24(6): 681-690

Adam Khan Mahaboob Basha, Sundarrajan Srinivasan, and Natarajan Srinivasan, Studies on thermally grown oxide as an interface between plasma-sprayed coatings and a nickel-based superalloy substrate, Int. J. Miner. Metall. Mater., 24(2017), No. 6, pp. 681-690. https://doi.org/10.1007/s12613-017-1451-0

Cite this article as:

Adam Khan Mahaboob Basha, Sundarrajan Srinivasan, and Natarajan Srinivasan, Studies on thermally grown oxide as an interface between plasma-sprayed coatings and a nickel-based superalloy substrate, Int. J. Miner. Metall. Mater., 24(2017), No. 6, pp. 681-690. https://doi.org/10.1007/s12613-017-1451-0

Citation:

PDF( 1748 KB)

Research Article

Studies on thermally grown oxide as an interface between plasma-sprayed coatings and a nickel-based superalloy substrate

+ Author Affiliations

Corresponding author:
Adam Khan Mahaboob Basha E-mail: adamkhanm@gmail.com
Received: 31 October 2016; Revised: 8 January 2017; Accepted: 12 January 2017

Abstract

Abstract

A thermally grown oxide layer formed by hot corrosion was investigated as an interface between plasma-sprayed coatings and a nickel-based superalloy substrate. The hot corrosion mechanism of NiCr-Cr₂O₃ and Al₂O₃-40wt% TiO₂ (A40T) plasma coated Inconel 617 was evaluated. The experiments were carried out at 1000℃ using a combination of Na₂SO₄, NaCl, and ₂O₅ salts to simulate the conditions of a gas turbine in a marine environment. The hot corrosion results revealed the spallation and dissolution of oxides upon prolonged exposure. Optical images and scanning electron micrographs of the exposed samples revealed the formation of oxide scale and provided details of its morphology in NiCr-Cr₂O₃ coated samples. Microstructure characterization of A40T coatings demonstrated a thermally grown oxide (TGO) layer at 1000℃. Increasing the thickness of the TGO layer decreased the corrosion resistance. The elemental analysis and image mapping revealed the migration of active elements from the substrate and coatings toward the corrosive environment.
- corrosion;
- coatings;
- superalloy;
- oxides

FullText(HTML)

Supplements(0)

References(38)

References

[1]	S. Kamal, R. Jayaganthan, and S. Prakash, Hot corrosion studies of detonation-gun-sprayed nicraly+0.4wt% CeO₂ coated superalloys in molten salt environment, J. Mater. Eng. Perform., 20(2011), No. 6, p. 1068.
[2]	C. Che, G.Q. Wu, H.Y. Qi, Z. Huang, and X.G. Yang, Effect of bond coat surface roughness on oxidation behaviour of air plasma sprayed thermal barrier coatings, Surf. Eng., 24(2008), No. 4, p. 276.
[3]	Y. Wang, M.X. Li, and H.L. Suo, Mechanical properties of YSZ thermal barrier coatings with segmented structure, Surf. Eng., 28(2012), No. 5, p. 329.
[4]	X. Ren, F.H. Wang, and X. Wang, High-temperature oxidation and hot corrosion behaviors of the NiCr-CrAl coating on a nickel-based superalloy, Surf. Coat. Technol., 198(2005), No. 1-3, p. 425.
[5]	R.A. Mahesh, R. Jayaganthan, and S. Prakash, High temperature oxidation studies on HVOF sprayed NiCrAl coatings on superalloys, Surf. Eng., 27(2011), No. 5, p. 332.
[6]	R.A. Mahesh, R. Jayaganthan, and S. Prakash, Evaluation of hot corrosion behaviour of HVOF sprayed Ni-5Al and NiCrAl coatings in coal fired boiler environment, Surf. Eng., 26(2010), No. 6, p. 413.
[7]	X.Y. Xie, H.B. Guo, S.K. Gong, and H.B. Xu, Hot corrosion behavior of double-ceramic-layer LaTi₂Al₉O₁₉/YSZ thermal barrier coatings, Chin. J. Aeronaut., 25(2012), No. 1, p. 137.
[8]	G. Kaushal, N. Kaur, H. Singh, and S. Prakash, Effect of zirconium addition in HVOF sprayed Ni-20Cr coating, Surf. Eng., 29(2013), No. 1, p. 46.
[9]	S. Matthews, B. James, and M. Hyland, High temperature erosion-oxidation of Cr₃C₂-NiCr thermal spray coatings under simulated turbine conditions, Corros. Sci., 70(2013), p. 203.
[10]	D.S. Balint and J.W. Hutchinson, An analytical model of rumpling in thermal barrier coatings, J. Mech. Phys. Solids, 53(2005), No. 4, p. 949.
[11]	M.W. Chen, R.T. Ott, T.C. Hufnagel, P.K. Wright, and K.J. Hemker, Microstructural evolution of platinum modified nickel aluminide bond coat during thermal cycling, Surf. Coat. Technol., 163-164(2003), No. 29, p. 25.
[12]	H.B. Zhao, Z. Yu, and H.N.G. Wadley, The influence of coating compliance on the delamination of thermal barrier coatings, Surf. Coat. Technol., 204(2010), No. 15, p. 2432.
[13]	R. McPherson, A review of microstructure and properties of plasma sprayed ceramic coatings, Surf. Coat. Technol., 39-40(1989), p. 173.
[14]	I.A. Mahmood, W.W. Jameel, and L.A. Khaleel, Improved oxidation resistance for thermal barrier ceramic coating protect, Int. J. Res. Eng. Technol., 1(2013), No. 5, p. 77.
[15]	A. Rico, J. Rodríguez, and E. Otero, High temperature oxidation behaviour of nanostructured alumina-titania APS coatings, Oxid. Met., 73(2010), No. 5, p. 531.
[16]	L.J. Zhu, S.L. Zhu, and F.H. Wang, Hot corrosion behaviour of a Ni+CrAlYSiN composite coating in Na₂SO₄-25 wt% NaCl melt, Appl. Surf. Sci., 268(2013), No. 1, p. 103.
[17]	M. Daroonparvar, M.A.M. Yajid, N.M. Yusof, and M.S. Hussain, Improved thermally grown oxide scale in air plasma sprayed NiCrAlY/Nano-YSZ coatings, J. Nanomater., 2013(2013), art. No. 520104.
[18]	L.Y. Ni, C. Liu, H. Huang, and C.G. Zhou, Thermal cycling behaviour of thermal barrier coatings with HVOF NiCrAlY bond coat, J. Therm. Spray Technol., 20(2011), No. 5, p. 1133.
[19]	H.B. Xu, H.B. Guo, F.S. Liu, and S.K. Gong, Development of gradient thermal barrier coatings and their hot-fatigue behavior, Surf. Coat. Technol., 130(2000), No. 1, p. 133.
[20]	V.K. Tolpygo and D.R. Clarke, Surface rumpling of a (Ni,Pt) Al bond coat induced by cyclic oxidation, Acta Mater., 48(2000), No. 13, p. 3283.
[21]	Z.L. Tang, F.H. Wang, and W.T. Wu, Effect of Al₂O₃ and enamel coatings on 900℃ oxidation and hot corrosion behaviors of gamma-TiAl, Mater. Sci. Eng. A, 276(2000), No. 1-2, p. 70.
[22]	I. Gurrappa and A.S. Rao, Thermal barrier coatings for enhanced efficiency of gas turbine engines, Surf. Coat. Technol., 201(2006), No. 6, p. 3016.
[23]	I. Gurrappa, I.V.S. Yashwanth, and A.K. Gogia, The behaviour of superalloys in marine gas turbine engine conditions, J. Surf. Eng. Mater. Adv. Technol., 1(2011), No. 3, p. 144.
[24]	J.R. Blachere and F.S. Pettit, High Temperature Corrosion of Ceramics, William Andrew Publishing, USA, 1989, p. 89.
[25]	X. Huang, P. Puetz, Q. Yang, and Z. Tang, Characterisation of transient oxide formation on NiCrAlY after heat treatment in vacuum, Surf. Eng., 27(2011), No. 5, p. 368.
[26]	A. Rahman, R. Jayaganthan, S. Prakash, V. Chawla, and R. Chandra, Cyclic high temperature oxidation behaviour of sputtered Cr/Al multilayer coatings on superalloy, Surf. Eng., 27(2011), No. 5, p. 393.
[27]	S. Kamal, R. Jayaganthan, and S. Prakash, Hot corrosion behaviour of D-gun sprayed NiCoCrAlYTa coated superalloys at 900℃ in molten salt environment, Surf. Eng., 26(2010), No. 6, p. 453.
[28]	J.R. Davis, Nickel, Cobalt, and Their Alloys, ASM International, Materials Park, Ohio, 2000, p. 14.
[29]	H.C. Graham and H.H. Davis, Oxidation/vaporization kinetics of Cr₂O₃, J. Am. Ceram. Soc., 54(1971), No. 2, p. 89.
[30]	M.H. Guo, Q.M. Wang, P.L. Ke, J. Gong, C. Sun, R.F. Huang, and L.S. Wen, The preparation and hot corrosion resistance of gradient NiCoCrAlYSiB coatings, Surf. Coat. Technol., 200(2006), No. 12-13, p. 3942.
[31]	M. Qiao and C.G. Zhou, Hot corrosion behavior of Co modified NiAl coating on nickel base superalloys, Corros. Sci., 63(2012), p. 239.
[32]	X.S. Zhao and C.G. Zhou, Effect of Y₂O₃ content in the pack on microstructure and hot corrosion resistance of Y-Co-modified aluminide coating, Corros. Sci., 86(2014), p. 223.
[33]	H.Y. He, Z.J Liu, W. Wang, and C.G. Zhou, Microstructure and hot corrosion behavior of Co-Si modified aluminide coating on nickel based superalloys, Corros. Sci., 100(2015), p. 466.
[34]	Y.W. Pei and C.G. Zhou, Improved hot corrosion resistance of Dy-Co-modified aluminide coating by pack cementation process on nickel base superalloys, Corros. Sci., 112(2016), p. 710.
[35]	D.W. McKee, D.A. Shore, and K.L. Lurthra, The effect of SO₂ and NaCl on high temperature hot corrosion, J. Electrochem. Soc., 125(1978), No. 3, p. 411.
[36]	M.K. Hossain and S.R.J. Saunders, A microstructural study of the influence of NaCl vapor on the oxidation of a Ni-Cr-Al alloy at 850℃, Oxid. Met., 12(1978), No. 1, p. 1.
[37]	L.A. Klinkova and E.A. Ukshe, Solution of corundum in fused vanadates, Russ. J. Inorg. Chem., 20(1975), No. 2, p. 799.
[38]	P.S. Sidky and M.G. Hocking, The hot corrosion of Ni-based ternary alloys and superalloys for application in gas turbines employing residual fuels, Corros. Sci., 27(1987), No. 5, p. 499.