Abstract
In this study, a continuous and dense FeAl/Al2O3 gradient coating was prepared on the surface of 316L stainless steel by hot-dipping aluminizing, vacuum annealing and low-oxygen pressure oxidation. The results showed that when a hot-dipping pure aluminum was applied, the alloy compound layer was composed of (Fe, Cr, Ni)2Al5 and (Fe, Cr, Ni)Al3 phases. When the Si content in the bath was higher than 2.5 wt.%, a new intermetallic compound, Al7(Fe, Cr)2Si, appeared at the interface, and the thickness of the metal compound layer decreased continuously upon increasing the silicon content in the melt pool. When the hot-dipped sample was annealed in vacuum at 900 °C for 3 h, the brittle (Fe, Cr, Ni)2Al5 phase was transformed into a ductile (Fe, Cr, Ni)Al phase. As low-oxygen pressure oxidation progressed, FeAl/Al2O3 gradient coatings were formed on the surface layer. The oxide film formed by the Al-2.5 Si wt.% sample was flatter and denser, which significantly improved its high-temperature oxidation resistance. Reducing the oxygen partial pressure promoted the external oxidation of Al element and the formation of Al2O3 oxide film.
Similar content being viewed by others
References
J. Huang, H. Xie, L.M. Luo, X. Zan, D.G. Liu, and Y.C. Wu, Preparation and Properties of FeAl/Al2O3 Composite Tritium Permeation Barrier Coating on Surface of 316L Stainless Steel, Surf. Coat. Technol., 2020, 383, 125282. https://doi.org/10.1016/j.surfcoat.2019.125282
X. Hu, T.G. Lach, and K.A. Terrani, Deuterium Permeation and Retention in 316L Stainless Steel Manufactured by Laser Powder Bed Fusion, J. Nucl. Mater., 2021, 548, 152871. https://doi.org/10.1016/j.jnucmat.2021.152871
J. Lin, F. Chen, F. Liu, D. Xu, J. Gao, and X. Tang, Hydrogen Permeation Behavior and Hydrogen-Induced Defects in 316L Stainless Steels Manufactured by Additive Manufacturing, Mater. Chem. Phys., 2020, 250, 123038. https://doi.org/10.1016/j.matchemphys.2020.123038
M. Moshref-Javadi, H. Edris, A. Shafyei, H. Salimi-Jazi, and E. Abdolvand, Evaluation of Hydrogen Permeation Through Standalone Thermally Sprayed Coatings of AISI 316L Stainless Steel, Int. J. Hydrogen. Energ., 2018, 43(9), p 4657-4670. https://doi.org/10.1016/j.ijhydene.2018.01.021
Y. Wu, S. Wang, S. Li, D. He, X. Liu, L. Jiang, and H. Huang, Deuterium Permeation Properties of Er2O3/Cr2O3 Composite Coating Prepared by MOCVD on 316L Stainless Steel, Fusion Eng. Des., 2016, 113, p 205-210. https://doi.org/10.1016/j.fusengdes.2016.09.007
S.P. Sah, E. Tada, and A. Nishikata, Enhancing Corrosion Resistance of Type 310S Stainless Steelin Carbonate melt by hot-dip Aluminizing, J. Electrochem. Soc., 2018, 165(7), p C403-C411. https://doi.org/10.1149/2.1241807jes
S. Sharafi, and M.R. Farhang, Effect of Aluminizing on Surface Microstructure of an HH309 Stainless Steel, Surf. Coat. Technol., 2006, 200(16–17), p 5048-5051. https://doi.org/10.1016/j.surfcoat.2005.05.024
H. Barekatain, and S.M. Mousavi Khoei, High-Temperature Oxidation Behaviors of Plasma Electrolytic Oxidation Coating on Hot-Dip Aluminized HP40Nb Alloy, Surf. Coat. Technol., 2020, 384, p 125339. https://doi.org/10.1016/j.surfcoat.2020.125339
G.Q. Zhang, S.S. Zhang, R.B. Song, and C.H. Cai, Effect of Mg and Si Contents on Hot-Dip 55Al-Zn Plating: Experimental and Molecular Dynamics Simulation, Mater. Today Commun., 2023, 35, 106131. https://doi.org/10.1016/j.mtcomm.2023.106131
Z. Zhan, Z. Liu, J. Liu, L. Li, Z. Li, and P. Liao, Microstructure and High-Temperature Corrosion behaviors of Aluminide Coatings by low-Temperature Pack Aluminizing Process, Appl. Surf. Sci., 2010, 256(12), p 3874-3879. https://doi.org/10.1016/j.apsusc.2010.01.043
J. Huang, J. Lu, X. Zhang, Z. Yang, Y. Zhou, Z. Yang, Y. Dang, and Y. Yuan, Preparation and Characterization of Slurry Aluminide Coating on TP347HFG Stainless Steel, Metall. Mater. Trans. A, 2019, 50, p 3776-3784. https://doi.org/10.1007/s11661-019-05296-9
A. Anastassiou, C. Christoglou, and G.N. Angelopoulos, Formation of Aluminide Coatings on Ni and Austenitic 316 Stainless Steel by a Low Temperature FBCVD Process, Surf. Coat. Technol., 2010, 204(14), p 2240-2245. https://doi.org/10.1016/j.surfcoat.2009.12.018
F.J. Pérez, M.P. Hierro, J.A. Trilleros, M.C. Carpintero, L. Sánchez, J.M. Brossard, and F.J. Bolívar, Ironaluminide Coatings on Ferritic Steels by CVD-FBR Technology, Intermetallics, 2006, 14(7), p 811-817. https://doi.org/10.1016/j.intermet.2005.12.010
C.F. Kuang, Z.W. Zheng, M.L. Wang, Q. Xu, and S.G. Zhang, Effect of Hot-Dip Galvanizing Processes on the Microstructure and Mechanical Properties of 600-MPa Hot-Dip Galvanized Dual-Phase Steel, Int. J. Min. Met. Mater., 2017, 24, p 1379-1383. https://doi.org/10.1007/s12613-017-1530-2
Y. Li, Y. Liu, and J. Yang, First Principle Calculations and Mechanical Properties of the Intermetallic Compounds in a Laser Welded Steel/Aluminum Joint, Opt. Laser Technol., 2020, 122, 105875. https://doi.org/10.1016/j.optlastec.2019.105875
G. Xu, K. Wang, X. Yang, H. Wang, Q. Ding, and J. Wen, Review on Corrosion Resistance of Mild Steels in Liquid Aluminum, J. Mater. Sci. Technol., 2021, 71, p 12-22. https://doi.org/10.1016/j.jmst.2020.08.052
X. Chen, Q. Huang, Z. Yan, Y. Song, S. Liu, and Z. Jiang, Preliminary Study of HDA Coating on CLAM Steel Followed by High Temperature Oxidation, J. Nucl. Mater., 2013, 442(1–3), p S597-S602. https://doi.org/10.1016/j.jnucmat.2013.03.011
H. Azimaee, M. Sarfaraz, M. Mirjalili, and K. Aminian, Effect of Silicon and Manganese on the Kinetics and Morphology of the Intermetallic Layer Growth During Hot-Dip Aluminizing, Surf. Coat. Technol., 2019, 357, p 483-496. https://doi.org/10.1016/j.surfcoat.2018.10.035
H. Wang, S. Sun, X. Li, J. Wang, and X. Su, Effect of Silicon on Interfacial Reaction Andmorphology of Hot-Dip Aluminizing, J. Mater. Res. Technol., 2022, 20, p 3723-3734. https://doi.org/10.1016/j.jmrt.2022.08.095
J.L. Song, S.B. Lin, C.L. Yang, and C.L. Fan, Effects of Si Additions on Intermetallic Compound Layer of Aluminum Steel TIG Welding–Brazing Joint, J. Alloys Compd., 2009, 488(1), p 217-222. https://doi.org/10.1016/j.jallcom.2009.08.084
W.J. Cheng, and C.J. Wang, Effect of Silicon on the Formation of Intermetallic Phases in Aluminide Coating on Mild Steel, Intermetallics, 2011, 19(10), p 1455–1460. https://doi.org/10.1016/j.intermet.2011.05.013
T. Bergh, S.M. Arbo, A.B. Hagen, J. Blindheim, J. Friis, M.Z. Khalid, I.G. Ringdalen, R. Holmestad, I. Westermann, and P.E. Vullum, On Intermetallic Phases Formed During Interdiffusion Between Aluminium Alloys and Stainless Steel, Intermetallics, 2022, 142, 107443. https://doi.org/10.1016/j.intermet.2021.107443
J. Zang, P. Song, J. Feng, X. Xiong, R. Chen, G. Liu, and J. Lu, Oxidation Behaviour of the Nickel-Based Superalloy DZ125 Hot-Dipped with Al Coatings Doped by Si, Corros. Sci., 2016, 112, p 170-179. https://doi.org/10.1016/j.corsci.2016.07.020
Y.Y. Chang, W.J. Cheng, and C.J. Wang, Growth and Surface Morphology of Hot-Dip Al–Si on 9Cr-1Mo Steel, Mater Charact, 2009, 60(2), p 144-149. https://doi.org/10.1016/j.matchar.2008.08.003
F.C. Yin, M.X. Zhao, Y.X. Liu, W. Han, and Z. Li, Effect of Si on Growth Kinetics of Intermetallic Compounds During Reaction Between Solid iron and Molten Aluminum, Trans. Nonferrous Met. Soc. China, 2013, 23(2), p 556-561.
B. Lemmens, H. Springer, I. De Graeve, J. De Strycker, D. Raabe, and K. Verbeken, Effect of Silicon on the Microstructure and Growth Kinetics of Intermetallic Phases Formed During hot-Dip Aluminizing of Ferritic Steel, Surf. Coat. Technol., 2017, 319, p 104-109. https://doi.org/10.1016/j.surfcoat.2017.03.040
M. Hasegawa. Chapter 3.3-Ellingham diagram, Treatise Process Metall, (Elsevier, 2014) 507-516. https://doi.org/10.1016/B978-0-08-096986-2.00032-1.
K. Kruska, D.K. Schreiber, M.J. Olszta, B.J. Riley, and S.M. Bruemmer, Temperature-Dependent Selective Oxidation Processes for Ni-5Cr and Ni-4Al, Corros. Sci., 2018, 139, p 309-318. https://doi.org/10.1016/j.corsci.2018.04.037
L. Latu-Romain, S. Mathieu, M. Vilasi, G. Renou, S. Coindeau, A. Galerie, and Y. Wouters, The Role of Oxygen Partial Pressure on the Nature of the Oxide Scale on a NiCr Model Alloy, Oxid. Met., 2016, 88, p 481-493. https://doi.org/10.1007/s11085-016-9670-8
A. Van Alboom, B. Lemmens, B. Breitbach, E. De Grave, S. Cottenier, and K. Verbeken, Multi-Method Identification and Characterization of the Intermetallic Surface Layers of Hot-Dip Al-Coated Steel: FeAl3 or Fe4Al13 and Fe2Al5 or Fe2Al5+x, Surf. Coat. Technol., 2017, 324, p 419-428. https://doi.org/10.1016/j.surfcoat.2017.05.091
D. Shin, J.Y. Lee, H. Heo, and C.Y. Kang, Formation Procedure of Reaction Phases in Al Hot Dipping Process of Steel, Metals, 2018, 8(10), p 820. https://doi.org/10.3390/met8100820
F. Zarei, H. Nuranian, and K. Shirvani, Effect of Si Addition on the Microstructure and Oxidation Behaviour of Formed Aluminide Coating on HH309 Steel by Cast-Aluminizing, Surf. Coat. Technol., 2020, 394, 125901. https://doi.org/10.1016/j.surfcoat.2020.125901
Y. Du, J.C. Schuster, Z.K. Liu, R. Hu, P. Nash, W. Sun, W. Zhang, J. Wang, L. Zhang, C. Tang, Z. Zhu, S. Liu, Y. Ouyang, W. Zhang, and N. Krendelsberger, A thermodynamic Description of the Al-Fe-Si System Over the Whole Composition and Temperature Ranges via a Hybrid Approach of CALPHAD and key Experiments, Intermetallics, 2008, 16(4), p 554-570. https://doi.org/10.1016/j.intermet.2008.01.003
V.G. Shmorgun, A.I. Bogdanov, V.P. Kulevich, L.D. Iskhakova, and A.O. Taube, Microstructureand Phase Composition of Diffusion Coating Formed in NiCr Alloys by Hot-Dip Aluminizing, Surf. Interfaces., 2021, 23, 100988. https://doi.org/10.1016/j.surfin.2021.100988
Y. Wang, N. Deng, Z.J. Zhou, and Z.F. Tong, Influence of Heating Temperature and Holding time on the Formation sequence of Iron Aluminides at the Interface of Fe/Al Coatings, Mater. Today Commun., 2021, 28, 102516. https://doi.org/10.1016/j.mtcomm.2021.102516
X. Li, A. Scherf, M. Heilmaier, and F. Stein, The Al-Rich Part of the Fe-Al Phase Diagram, J. Phase. Equilib. Diff., 2016, 37, p 162-173. https://doi.org/10.1007/s11669-015-0446-7
F. Zarei, H. Nuranian, and K. Shirvani, Characterization. Growth Kinetics and High-Temperature Oxidation Behavior of Aluminide Coating Formed on HH309 Stainless Steel by Casting and Subsequent Heat Treatment, Intermetallics, 2020, 120, p 106742. https://doi.org/10.1016/j.intermet.2020.106742
P. Huilgol, K.R. Udupa, and K.U. Bhat, Microstructural Investigations on the Hot-Dip Aluminized AISI 321 Stainless Steel after Diffusion Treatment, Surf. Coat. Technol., 2019, 375, p 544-553. https://doi.org/10.1016/j.surfcoat.2019.07.031
H.M. Wang, and G. Duan, Wear and Corrosion Behavior of Laser Clad Cr3Si Reinforced Intermetallic Composite Coatings, Intermetallics, 2003, 11(8), p 755-762. https://doi.org/10.1016/S0966-9795(03)00078-5
G. Duan, and H.M. Wang, Microstructure of Laser Melted/Rapidly Solidified γ/Cr3Si Metal Silicide “In Situ” Composites, J. Mater. Sci., 2002, 37, p 1981-1985. https://doi.org/10.1023/A:1015295014177
A. Bahadur, and O.N. Mohanty, Structural Studies of Hot Dip Aluminized Coatings on Mild Steel, Mater. T. Jim., 1991, 32(11), p 1053-1061.
S. Kobayashi, and T. Yakou, Control of Intermetallic Compound Layers at Interface Between Steel and Aluminum by Diffusion-Treatment, Mat. Sci. Eng. A-Struct., 2002, 338(1), p 44-53. https://doi.org/10.1016/S0921-5093(02)00053-9
N. Israelsson, J. Engkvist, K. Hellstrom, M. Halvarsson, J.E. Svensson, and L.G. Johansson, KCl-Induced Corrosion of an FeCrAl Alloy at 600 °C in O2+ H2O Environment: The Effect of Pre-Oxidation, Oxid. Met., 2015, 83(1–2), p 29-53. https://doi.org/10.1007/s11085-014-9507-2
X.W. Fang, Y. Wang, Y. Zhang, S.J. Feng, J.Y. Du, D.W. Liu, T.T. Ouyang, J.P. Suo, and S.Z. Cai, Improving the Corrosion Resistance of Fe-21Cr-9Mn Alloy in Liquid Zinc by Heat Treatment, Corros. Sci., 2016, 111, p 362-369. https://doi.org/10.1016/j.corsci.2016.05.018
E. Airiskallio, E. Nurmi, M.H. Heinonen, I.J. Väyrynen, K. Kokko, M. Ropo, M.P.J. Punkkinen, H. Pitkänen, M. Alatalo, J. Kollár, B. Johansson, and L. Vitos, High Temperature Oxidation of Fe-Al and Fe-Cr-Al alloys: The Role of Cr as a Chemically Active Element, Corros. Sci., 2010, 52, p 394-3404. https://doi.org/10.1016/j.corsci.2010.06.019
J. Shen, S. Liu, X.H. Guo, and Y. Niu, Simultaneous Oxidation and Carburization of a Fe-9Cr Alloy Under Different Oxygen Pressures at 800 °C, Corros. Sci., 2017, 129, p 1-15. https://doi.org/10.1016/j.corsci.2017.09.021
P. Jang, and S.C. Shin, Formation of Particulate Fe-Al Films by Selective Oxidation of Aluminum, Met. Mater. Int., 2013, 19(5), p 1163-1166. https://doi.org/10.1007/s12540-013-5036-9
L. Mikkelsen, and S. Linderoth, High Temperature Oxidation of Fe-Cr Alloy in O2–H2–H2O Atmospheres; Microstructure and Kinetics, Mater. Sci. Eng., 2003, 361(1), p 198-212. https://doi.org/10.1016/S0921-5093(03)00527-6
X. Zhang, C.C. Silva, C. Liu, M. Prabhakar, and M. Rohwerder, Selective Oxidation of Ternary FeMn-Si Alloys During Annealing Process, Corros. Sci., 2020, 174, p 108859. https://doi.org/10.1016/j.corsci.2020.108859
Acknowledgments
We would like to express our gratitude for financial supports from the National Nature Science Foundation of China (Grant Nos. 52171003 and 52271005) and the Jiangsu Provincial Higher Education Key Discipline Construction Grant Program.
Author information
Authors and Affiliations
Corresponding authors
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Yuan, B., Deng, X., Guo, Z. et al. Effects of Annealing and Oxidation on the Microstructure of Hot-Dipped Aluminum–Silicon Coating of 316L Stainless Steel. J. Phase Equilib. Diffus. 45, 114–131 (2024). https://doi.org/10.1007/s11669-024-01092-0
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11669-024-01092-0