Skip to main content

Advertisement

SpringerLink
Log in

Stepwise Depletion of Coating Elements as a Result of Hot Corrosion of NiCrAlY Coatings

  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

Present investigation deals with the hot corrosion behaviour of the NiCrAlY coatings deposited by HVOF technique on Superni76 under cyclic conditions at 900  °C in the presence of Na2SO4 + 60% V2O5 salt. The weight change behaviour of the coatings was followed with time up to 200 cycles and K p value was calculated for the hot corrosion process. Surface and cross-section of the corroded samples were examined by FESEM/EDS and XRD to follow the progress of corrosion up to 200 cycles. In earlier cycles, the corrosive species oxidised top surface of the coatings. With increasing number of cycles, oxidation of the coatings occurred up to 40-μm depth. A Cr-depleted band was seen below the oxide scale. Further increase in number of cycles led to migration and oxidation of Al to form Al2O3 sublayer at coating/scale interface, thereby leading to formation of Al-depleted zone in the coating below the Al2O3 sublayer. The corrosion resistance of the NiCrAlY coatings is attributed to the formation of the continuous and dense Al2O3 sublayer at the coating/scale interface, which acts as barrier to the migration of Cr to the surface. The appearance of Al3Y after 100 and 200 cycles also contributes to the increased corrosion resistance of coatings after 100 and 200 cycles.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

References

  1. W. Brandl, D. Toma, and H.J. Grabke, The Characteristics of Alumina Scales Formed on HVOF-Sprayed MCrAlY Coatings, Surf. Coatings Technol., 1998, 108–109, p 10–15 [in English]

    Article  Google Scholar 

  2. Y.N. Wu, M. Qin, Z.C. Feng, Y. Liang, C. Sun, and F.H. Wang, Improved Oxidation Resistance of NiCrAlY Coatings, Mater. Lett., 2003, 57, p 2404–2408 [in English]

    Article  Google Scholar 

  3. M.H. Li, Z.Y. Zhang, X.F. Sun, J.G. Li, F.S. Yin, W.Y. Hu, H.R. Guan, and Z.Q. Hu, Oxidation Behavior of Sputter-Deposited NiCrAlY Coating, Sur. Coat. Tech., 2003, 165, p 241–247 ([in English])

    Article  Google Scholar 

  4. F.H. Yuan, Z.X. Chen, Z.W. Huang, Z.G. Wang, and S.J. Zhu, Oxidation Behavior of Thermal Barrier Coatings with HVOF and Detonation-Sprayed NiCrAlY Bondcoats, Corros. Sci., 2008, 50, p 1608–1617 ([in English])

    Article  Google Scholar 

  5. Y.J. Zhang, X.F. Sun, H.R. Guan, and Z.Q. Hu, Isothermal Oxidation Behavior of Detonation Gun Sprayed NiCrAlY Coating, Surf. Coat. Tech., 2002, 161, p 302–305 [in English]

    Article  Google Scholar 

  6. B. Wang, J. Gong, A.Y. Wang, C. Sun, R.F. Huang, and L.S. Wen, Oxidation Behaviour of NiCrAlY Coatings on Ni-Based Superalloy, Surf. Coat. Tech., 2002, 149, p 70–75 [in English]

    Article  Google Scholar 

  7. M.R. Khajavi and M.H. Shariat, Failure of First Stage Gas Turbine Blades, Eng. Fail. Anal., 2004, 11, p 589–597 ([in English])

    Article  Google Scholar 

  8. R.A. Mahesh, R. Jayaganthan, and S. Prakash, Evaluation of Hot Corrosion Behaviour of HVOF Sprayed NiCrAl Coating on Superalloys at 900 °C, Mater. Chem. Phys., 2008, 111, p 524–533 ([in English])

    Article  Google Scholar 

  9. J.L. Tristancho-Reyes, J.G. Chacón-Naval, D.Y. Peña-Ballesteros, C. Gaona-Tiburcio, J.G. Gonzalez-Rodriguez, A. Martínez-Villafañe, and F. Almeraya-Calderón, Hot Corrosion Behaviour of NiCrFeNbMoTiAl Coating in Molten Salts at 700 °C by Electrochemical Techniques, Int. J. Electrochem. Sci., 2011, 6, p 432–441 ([in English])

    Google Scholar 

  10. I. Gurrappa, Hot Corrosion of Protective Coatings, Mater. Manuf. Process., 2000, 15(5), p 761–773 ([in English])

    Article  Google Scholar 

  11. H. Singh, D. Puri, S. Prakas, and T.K. Ghosh, Hot Corrosion of a Plasma Sprayed Ni3Al Coating on a Ni-Base Superalloy, Mater. Corros., 2007, 58(11), p 857–866 ([in English])

    Article  Google Scholar 

  12. D.A. Shifler, Y.li Ma, B.E. Rodman, Evaluating the Hot Corrosion Effects of High Temperature Coatings for Marine Gas Turbines, Corrosion, April 3–7, Houston, TX, 2005, Nace International, 2005

  13. T.S. Sidhu, S. Prakash, and R.D. Agrwal, Hot Corrosion Performance of Nickel Based Coatings, Curr. Sci. India, 2006, 90(1), p 41–47 ([in English])

    Google Scholar 

  14. M.C. Mayoral, J.M. Andrés, M.T. Bona, V. Higuera, and F.J. Belzunce, Aluminium Depletion in NiCrAlY Bond Coatings by Hot Corrosion as a Function of Projection System, Surf. Coat. Tech., 2008, 202, p 1816–1824 ([in English])

    Article  Google Scholar 

  15. S. Prakash, D. Puri, and H. Singh, Hot Corrosion Behaviour of Plasma Sprayed Coatings on a Ni Based Superalloy in Na2SO4 + V2O5 Environment, ISIJ int, 2003, 45(6), p 886–895 ([in English])

    Article  Google Scholar 

  16. S. Mohsen, A. Abbas, and K. Akira, Bond Coat Oxidation and Hot Corrosion Behaviour of Plasma Sprayed YSZ Coating on Ni Based Superalloy, Trans. JWRI, 2007, 36(1), p 41–45 [in English]

    Google Scholar 

  17. D. Gond, R.S. Lalbonmdre, D. Puri, and S. Prakash, High Temperature Oxidation and Hot Corrosion Behaviour of Yttria- Stabilised Zirconia as Plasma Sprayed Coating in Air and Salt at 900 °C Under Cyclic Condition, J. Miner. Mater. Charact. Eng., 2012, 11(3), p 285–302 ([in English])

    Google Scholar 

  18. T.S. Sidhu, R.D. Agrawal, and S. Prakash, Hot Corrosion of Some Superalloys and Role of High-Velocity Oxy-Fuel Spray Coatings—A Review, Surf. Coat. Tech., 2005, 198, p 441–446 ([in English])

    Article  Google Scholar 

  19. L. Zhao and E. Lugscheider, Influence of the Spraying Processes on the Properties of 316L Stainless Steel Coatings, Surf. Coat. Tech., 2002, 162, p 6–10 ([in English])

    Article  Google Scholar 

  20. N. Rana, R. Jayaganthan, and S. Prakash, Microstructural Features and Oxidation Behaviour of NiCrAlY Coatings Obtained by HVOF Process, Adv Mater Res, 2012, 585, p 507–511 ([in English])

    Article  Google Scholar 

  21. G. Sreedhar, M. Alam, and V.S. Raja, Hot Corrosion Behaviour of Plasma Sprayed YSZ/Al2O3 Dispersed NiCrAlY Coatings on Inconel-718 Superalloy, Surf. Coat. Tech., 2009, 204, p 291–299 ([in English])

    Article  Google Scholar 

  22. S.M. Jiang, X. Peng, Z.B. Bao, S.C. Liu, Q.M. Wang, J. Gong, and C. Sun, Preparation and Hot Corrosion Behaviour of a MCrAlY + AlSiY Composite Coating, Corros. Sci., 2008, 50, p 3213–3220 ([in English])

    Article  Google Scholar 

  23. Y. Longa and M. Takemoto, High-Temperature Corrosion of Laser-Glazed Alloys in Na2SO4-V2O5, Corrosion, 1992, 48(7), p 599–607 ([in English])

    Article  Google Scholar 

  24. E.W.A. Young and J.H.W. Wit, An 18O Tracer Study on the Growth Mechanism of Alumina Scales on NiAl and NiAlY Alloys, Oxid Met, 1986, 26(5/6), p 351–361 ([in English])

    Article  Google Scholar 

  25. J. Swaminathan, S. Raghavan, and S.R. Iyer, Studies on the Hot Corrosion of Some Nickel-Base Superalloys by Vanadium Pentoxide, Trans. Indian Inst. Met., 1993, 46(3), p 175–181 ([in English])

    Google Scholar 

  26. Z.B. Bao, Q.M. Wang, W.Z. Li, X. Liu, J. Gong, T.Y. Xiong, and C. Sun, Preparation and Hot Corrosion Behaviour of an Al-Gradient NiCoCrAlYSiB Coating on a Ni-Base Superalloy, Corros. Sci., 2009, 51, p 860–867 ([in English])

    Article  Google Scholar 

  27. W.B. Bouaeshi and D.Y. Li, Effects of Y2O3 Addition on Microstructure, Mechanical Properties, Electrochemical Behavior, and Resistance to Corrosive Wear of Aluminum, Tribol. Int., 2007, 40(2), p 188–199 ([in English])

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, Roorkee, 247667, Uttarakhand, India

    Nidhi Rana, R. Jayaganthan & Satya Prakash

Authors
  1. Nidhi Rana
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. R. Jayaganthan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Satya Prakash
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Nidhi Rana.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Rana, N., Jayaganthan, R. & Prakash, S. Stepwise Depletion of Coating Elements as a Result of Hot Corrosion of NiCrAlY Coatings. J. of Materi Eng and Perform 23, 643–650 (2014). https://doi.org/10.1007/s11665-013-0774-x

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-013-0774-x

Keywords

Search

Navigation