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High-temperature oxidation of HVOF thermally sprayed NiCr–Cr3C2 coatings: microstructure and kinetics

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Abstract

In this study, 25 wt% Ni(Cr)–75 wt% Cr3C2 powder was thermally sprayed onto 304 stainless steel substrate to produce coatings of ~400-µm thick and the oxidation behaviour of the coatings was investigated. The kinetic behaviour of oxidation of freestanding coatings was investigated over short times at 650, 700 and 800 °C using the thermogravimetric analysis technique. The oxidation rate for all samples was parabolic in nature and the parabolic rate constant (k) increased with increasing temperature. The activation energy (Q) for oxidation was found to be around 226 kJ mol−1. Furnace oxidation tests were also carried out on the as-sprayed samples at 700 and 800 °C in laboratory air for times ranging from 1 h up to 16 days (384 h). The oxide scale growth, morphology and phase formation were investigated using scanning electron microscopy, energy dispersive X-ray analysis and X-ray diffraction. An oxide scale covered the surface of the cermet coating following oxidation at both 700 and 800 °C; the scale was significantly thicker at the higher temperature. It was found to be Cr2O3 and it covered both the metal matrix and the Cr3C2 particles present in the coating. The oxide grains had an angular shape after 16 days of exposure at both temperatures but the grain size was significantly larger after exposure at 800 °C.

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Acknowledgements

The authors would like to thank the technical staff in the Division of Materials, Mechanics and Structure Division at the Faculty of Engineering, University of Nottingham, specifically Dr. Deen Zhang and Mr. Rory Screaton for help with thermal spraying and Mr. Keith Dinsdale for his help with the TGA experiments.

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  1. Division of Materials, Mechanics & Structures, Faculty of Engineering, University of Nottingham, Nottingham, NG7 2RD, UK

    Y. Ding, T. Hussain & D. G. McCartney

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  1. Y. Ding
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  2. T. Hussain
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  3. D. G. McCartney
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Correspondence to T. Hussain.

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Ding, Y., Hussain, T. & McCartney, D.G. High-temperature oxidation of HVOF thermally sprayed NiCr–Cr3C2 coatings: microstructure and kinetics. J Mater Sci 50, 6808–6821 (2015). https://doi.org/10.1007/s10853-015-9238-z

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