Investigation of oxidation behavior and Thermal spray of mechanically milled CoNiCrAlY–YSZ powders

الموضوعات :

Mostafa Tahari ¹ (Department of Materials Engineering, Isfahan University of Technology, Isfahan, Iran.)
Morteza Shamanian Esfahani ² (Department of Materials Engineering, Isfahan University of Technology, Isfahan, Iran.)
Mehdi Salehi ³ (Department of Materials Engineering, Isfahan University of Technology, Isfahan, Iran.)

تاريخ الإرسال : 09 الأحد , محرم, 1436 تاريخ التأكيد : 27 الجمعة , صفر, 1436 تاريخ الإصدار : 10 الأحد , جمادى الأولى, 1436

الکلمات المفتاحية: CoNiCrAlY, Oxidation behavior, YSZ, High velocity oxy-fuel,

ملخص المقالة :

In this study, the effects of mechanical milling and YSZ reinforcing on oxidation behavior of CoNiCrAlY coatings were investigated. Various amounts of YSZ particles (0%, 5%, 10% and 15 wt.%) were mixed with commercial CoNiCrAlY powder and milled for 24 hrs. Then, the mechanically milled and commercial powders were deposited on Inconel 617 substrate using High Velocity Oxygen-Fuel (HVOF) process. Freestanding bodies of nanostructured and conventional HVOF CoNiCrAlY coatings were oxidized at 1000 °C for different times to form the thermally grown oxide layer. X-ray diffraction analysis, scanning electron microscopy and X-ray mapping were used to analyze the scales formed on the surface of the oxidized samples. The results showed that nanostructured coatings exhibited higher porosity due to undesirable morphology of feedstock powders. This factor accelerated diffusion rate of oxygen into coating body. On the other hand, undesireable oxidation of nanostructured particles during spraying leads to increase in the oxidation rate of coatings.

المصادر:

 

1. M. Seraffon, N. J. Simms, J. Sumner, J. R. Nicholls, “The development of new bond coat compositions for thermal barrier coating systems operating under industrial gas turbine conditions”, Surf. Coat. Technol. Vol. 206, 2011, pp. 1529-1537.


2. T. Liang, H. Guo, H. Peng,
   S. Gong,“Microstructural evolution of CoCrAlY bond coat on Ni-based superalloy DZ 125 at 1050 °C”, Surf. Coat. Technol., Vol. 205, 2011, pp. 4374-4379.


3. B. A. Pint, M. A. Bestor, J. A. Haynes, “Cyclic oxidation behavior of HVOF bond coatings deposited on La- and Y-doped superalloys”, Surf. Coat.Technol., Vol. 206, 2011,
   pp.1600-1604.


4. A. Keyvani, M. Saremi, M. H. Sohi,“Oxidation resistance of YSZ-alumina composites compared to normal YSZ TBC coatings at 1100^oC”, J. Alloys Compd.,Vol.509, 2011,
   pp. 8370-8379.


5. J. H. Lee, Pi-C. Tsai, J. w. Lee, “Cyclic oxidation behavior and microstructure evolution of aluminized, Pt-aluminizedhigh velocity oxygen fuel sprayed CoNiCrAlY coatings”, Thin Solid Films, Vol. 517, 2009,
   pp. 5253-5260.


6. H. Guo, L. Sun, H. Li, S. Gong, “High temperature oxidation behavior of hafnium modified NiAl bondcoat in EB-PVD thermal barrier coating system”, Thin Solid Films, Vol. 516, 2008, pp. 5732-5739.


7. F. Tang, L. Ajdelsztajn, G. E. Kim,
   V. Provenzano, J. M. Schoenung, “Effects of variations in coating materials and process conditions on the thermal cycle properties of NiCrAlY/YSZ thermal barrier coatings”, Mater. Sci. Eng. A, Vol. 425, 2006, pp. 94-101.


8. T. Sadowski, P. Golewski, “The influence of quantity and distribution of cooling channels of turbine elements on level of stresses in the protective layer TBC and the efficiency of cooling”, Com. Mater. Sci, Vol. 52, 2012,
   pp. 293-299.


9. L. Ajdelsztajn, J. A. Picas, G. E. Kim, F. L. Bastian, J. Schoenung, V. Provenzano, “Oxidation behavior of HVOF sprayed nanocrystallineNiCrAlY powder”, Mater. Sci. Eng. A, Vol. 338, 2002, pp. 33-43.


10. K. Ma, J. M. Schoenung, “Isothermal oxidation behavior of cryomilledNiCrAlY bond coat: Homogeneity and growth rate of TGO”, Surf. Coat. Technol., Vol. 205, 2011, PP. 5178-5185.


11. S. Kamal, R. Jayaganthan, S. Prakash,” Mechanical and microstructural characteristics of detonation gun sprayed NiCrAlY + 0.4 wt% CeO2 coatings on superalloys”, Mater. Chem. Phys. Vol. 122, 2010, pp. 262-268.


12. M. D. Ferdinando, A. Fossati, A. Lavacchi,
    U. Bardi, F. Borgioli,C. Borri, C. Giolli, A. Scrivani, “Isothermal oxidation resistance comparison between air plasma sprayed, vacuum plasma sprayed and high velocity oxygen fuel sprayed CoNiCrAlY bond coats”, Surf. Coat. Technol., Vol. 204, 2010,
    PP. 2499-2506.


13. L. Ajdelsztajn, D. Hulbert, A. Mukherjee, J. M. Schoenung, “Creep deformation mechanism of cryomilledNiCrAlY bond coat material”, Surf. Coat. Technol., Vol. 201, 2007, PP. 9462-9499.


14. F. Tang, L. Ajdelsztajn, G. E. Kim, V. Provenzano, J. M. Schoenung, “Improvement in oxidation behavior of nanostructured conicra1y bond coat dispersed with nano-size alumina particles”, International Conference of Fundamental Science of Energy 004, USA, 2002, P. 293.


15. L. Ajdelsztajn, F. Tang, G. E. Kim,
    V. Provenzano, J. M. Schoenung, “Synthesis and Oxidation Behavior of NanocrystallineMCrAlY Bond Coatings”,J. Therm. Spray Technol., Vol. 14, 2005,
    pp. 23-31.


16. D. Mercier, C. Kaplin, G. Goodall, G. Kim, M. Brochu, “Parameters influencing the oxidation behavior of cryomilledCoNiCrAlY”, Surf. Coat. Technol., Vol.205, 2010, pp. 2546-2552.


17. D. Mercier, B. D. Gauntt, M. Brochu,“Thermal stability and oxidation behavior of nanostructured NiCoCrAlY coatings”, Surf. Coat. Technol., Vol. 205, 2011, pp. 4162-4168.


18. M. Krasnowski, T. Kulik, “Nanocomposites obtained by mechanical alloying in Fe–Al–Ti–C system”, J. Alloys Compd., Vol. 448, 2008,
    pp. 227-233.


19. C. C. Koch,“Intermetallic matrix composites prepared by mechanical alloying—a review”, Mater. Sci. Eng. A, Vol. 244, 1998, pp. 39-48.


20. F. Valenza, M. L. Muolo, A. Passerone, “Wetting and interactions of Ni- and Co-based superalloys with different ceramic materials”, J. Mater. Sci., Vol. 45, 2010, pp. 2071-2079.


21. S. Deshpande, S. Sampath, H. Zhang, “Mechanisms of oxidation and its role in microstructural evolution of metallic thermal spray coatings—Case study for Ni–Al”, Surf. Coat. Technol., Vol.200, 2006, pp. 5395-5411.


22. S. Deshpande, A. Kulkarni, S. Sampath,
    H. Herman,“Application of image analysis for characterization of porosity in thermal spray coatings and correlation with small angle neutron scattering”,Surf.Coat. Technol.,
    Vol. 187, 2004, pp. 6-15.


23. D. J. Young, High Temperature Oxidation and Corrosion of Metals, 1rd ed., Elsevier, England, 2008, p. 348.


24. T. Kai, Z. Xiang, C. Hua, Z. J. shan,“Oxidation and hot corrosion behaviors of HVAF-sprayed conventional and nanostructured NiCrC coatings”, trans. Nonferrous met. Soc. China., Vol. 19, 2009, pp. 1151-1160.


25. R. A. Mahesh, R. Jayaganthan, S. Prakash,
    “A study on the oxidation behavior of HVOF sprayed NiCrAlY–0.4 wt.% CeO2 coatings on superalloys at elevated temperature”,Mater. Chem. Phys., Vol. 119, 2010, pp. 449-459.


26. T. Y. Choi, J. H. Yoon, K. S. Kim, K. O. Song, Y. K. Joo, W. Fang, S. H. Zhang, S. J. Youn,
    H. G. Chun, S. Y. Hwang,“A study on HVOF coatings of micron and nano WC–Co powders”, Surf. Coat. Technol., Vol.202, 2008,
    pp. 5556-5564.

27. D. Toma, W. Brandl, U. Koster, “Studies on the transient stage of oxidation of VPS and HVOF sprayed MCrAlY coatings”, Surf. Coat. Technol., Vol. 121, 1999, pp. 8-20.