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Investigation on the Oxidation Behavior of the NiCrAlY Bond-Coat with Low Al Content Sprayed by High Velocity Oxygen Fuel Method

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Abstract

The elemental interdiffusion between the bond-coat in the thermal barrier coatings (TBCs) system and the superalloy substrate has emerged as a critical factor affecting the service life of the TBCs-coated turbine blades in aero-engines. To address this issue, a NiCrAlY bond-coat with low Al content and high Y content was designed and sprayed on the superalloy using high velocity oxygen fuel method. The performance of the as-deposited coating was assessed through isothermal oxidation test at 1000 °C for durations ranging from 10 to 1000 h. The results revealed the precipitation of c-Y2O3 particles at the grain boundaries of the as-deposited coating. These particles appeared to impede the diffusion of coating elements, resulting in improved oxidation resistance. The oxidation mechanism of the as-deposited coating on the flat region was divided into two stages: the preferential oxidation of Al and the formation of spinel; the inward growth of alumina along with outward growth of spinel. In the concave area, the oxidation mechanism was characterized by a rapid thickening of the spinel phase and NiO, attributed to the thinner coating and special Ni diffusion method. Semi-molten particles formed an overlaying structure after oxidation as the elements diffused in surrounding areas, with only the Ni element remaining inside it. The designed low Al content NiCrAlY coating exhibits excellent oxidation resistance at 1000 °C.

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The raw data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study. The processed data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study.

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Acknowledgments

Financial support provided by Guangdong Basic and Applied Basic Research Foundation (No. 2022A1515110198), National Natural Science Foundation of China (No. 11890684 and No. U2341257), National Science and Technology Major Project (J2022-V-0003-0029), Innovation Capability Support Program of Shaanxi (Program No. 2022TD-28).

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Authors and Affiliations

  1. School of Advanced Materials and Nanotechnology, Xidian University, Xi’an, 710126, China

    Yuqi Xie, Junkai Liu, Junhui Luo, Qian Li, Jianquan Zhang, Li Yang & Yichun Zhou

  2. Shaanxi Key Laboratory of High-Orbits-Electron Materials and Protection Technology for Aerospace, Xidian University, Xi’an, 710126, China

    Junkai Liu, Li Yang & Yichun Zhou

  3. Guangzhou Institute of Technology, Xidian University, Guangzhou, 510555, China

    Junkai Liu, Li Yang & Yichun Zhou

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  1. Yuqi Xie
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Xie, Y., Liu, J., Luo, J. et al. Investigation on the Oxidation Behavior of the NiCrAlY Bond-Coat with Low Al Content Sprayed by High Velocity Oxygen Fuel Method. J Therm Spray Tech (2024). https://doi.org/10.1007/s11666-024-01767-7

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  • DOI: https://doi.org/10.1007/s11666-024-01767-7

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