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Enhancement of Corrosion Resistance of Al2O3 + Sm2SrAl2O7 Composite Thermal Barrier Coatings by Laser Treatment

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Abstract

The rare earth aluminate Sm2SrAl2O7 was synthesized in the laboratory through a molten salt synthesis technique at 1100 °C. A composite thermal barrier coating system on Inconel 718 substrate was developed with Al2O3–Sm2SrAl2O7 composite as the top coat and NiCrAlY as the bond coat using atmospheric plasma spraying. The surface of the plasma-sprayed coatings was treated using an Nd: YAG fiber laser to seal off the open porosities and reduce surface roughness. Hot corrosion tests on the laser-modified samples were performed at 700 °C and 900 °C, in aviation and marine corrosive conditions using 50 wt.% Na2SO4 + 50 wt.% V2O5 and 90 wt.% Na2SO4 + 5 wt.% V2O5 + 5 wt.% NaCl, respectively. The laser-treated samples showed higher resistance to failure than the as-coated samples under similar conditions. The corrosion products are identified, and the mechanisms involved are discussed in detail. The effect of surface modifications on the hot corrosion resistance of the coatings is investigated.

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Acknowledgements

The authors would like to thank the Metallizing Equipments, Jodhpur, and RRCAT, Indore, for the support offered in the development of samples. The authors are also thankful to CRF NITK for providing the characterization facilities. The help received from the operators Mr. Akash, Mrs. Aniz, Mr. Sanath, and Mr. Pradeep is greatly acknowledged.

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The authors did not receive support from any organization for the submitted work.

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  1. Metallurgical and Materials Engineering, National Institute of Technology, Surathkal, Karnataka, 575025, India

    Fredy James Joseph & Shashi Bhushan Arya

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  1. Fredy James Joseph
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Correspondence to Shashi Bhushan Arya.

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James Joseph, F., Arya, S.B. Enhancement of Corrosion Resistance of Al2O3 + Sm2SrAl2O7 Composite Thermal Barrier Coatings by Laser Treatment. Trans Indian Inst Met 77, 1381–1391 (2024). https://doi.org/10.1007/s12666-023-03159-x

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