Abstract
Pack cementation is an in situ chemical vapor deposition (CVD) batch process that has been used to produce corrosion- and wear-resistant coatings on inexpensive or otherwise inadequate substrates for over 75 years [1]. The traditional pack consists of four components: the substrate or parts to be coated; the masteralloy (i.e. a powder of the element or elements to be deposited on the surface of the parts, such as Cr and/or AI, Cr and/or Si); a halide salt activator or energizer (e.g. NaCl, NaF, NH4C1, etc.); and a relatively inert filler powder (e.g. Al2O3, SiO2, or SiC). The masteralloy powder, the halide salt activator, and the inert filler are mixed thoroughly, and the parts to be coated are buried in this mixture within a heat-resistant retort. Commercially, inversely stacked Inconel boxes are used as the retort. Inversely stacking the boxes creates pathways for the inert carrier gas. Depending on the size of the parts to be coated, the retort size ranges from small boxes approximately 35 cm × 35 cm × 35 cm to larger boxes approximately 90 cm × 90 cm × 50 cm. As an inlet for the carrier gas, an Inconel tube is attached to the outer box of the retort. The assembled retort is then sealed with fusible silicate. Experimentally, a cylinder of commercially pure alumina (Al2O3) with one end closed is used as the retort. The alumina retort size ranges from small cylinders approximately 5 cm outer diameter by 10 cm long to larger cylinders approximately 10 cm outer diameter by 20 cm long.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Preview
Unable to display preview. Download preview PDF.
References
Allison, G. and Hawkins, M.K. (1914) General Electric Review, 17, 947–51.
Van Aller, T. (1911) Treatment of metals. U.S. Patent 1,155,974.
Goward, G.W. and Cannon, L.W. (1988) Trans. ASME, 110(1), 150–4.
Goward, G.W. and Boone, D.H. (1971) Oxid. Metals, 3(5), 475–95.
Pichoir, R. (1978) Influence of the mode of formation on the oxidation and corrosion behavior of NiAl-type protective coatings, in Materials and Coatings to Resist High-Temperature Corrosion (eds D.R. Holmes and A. Rahmel), Applied Science Publishers, London, pp. 271–91.
Shankar, S. and Seigle, L.L. (1978) Metall. Trans. A, 9(10), 1467–76.
Parzuchowski, R.S. (1977) Thin Solid Films, 45, 349–55.
Akuezue, H.C. and Stringer, J. (1989) Multiphase diffusion and growth during aluminizing (Fe-Cr-Al system), in Diffusion Analysis and Applications (eds A.D. Romig, Jr. and M.A. Dayananda), The Metallurgical Society of AIME, pp. 337–60.
Miller, D.M., Kung, S.C., Scarberry, S.D. and Rapp, R.A. (1988) Oxid, of Metals, 29(3/4), 239–54.
Bangaru, N.V. and Krutenat, R.C. (1984) J. Vac. Sci. Technol., 2(4), 806–15.
Kelley, F.D. (1923) Trans. Amer. Electrochem. Soc, 43, 351–70.
Hoar, T.P. and Croom, E.A.G. (1951) J. Iron Steel Inst., Oct. 1951, pp. 101–7.
Menzies, I.A. and Mortimer, D. (1965) Corr. Sci., 5, 539–58.
Ravi, V.A. (1988) Simultaneous chromizing-aluminizing of nickel and nickel-base alloys by halide-activated pack cementation. Ph.D. dissertation, The Ohio State University.
Meier, G.H., Cheng, C, Perkins, R.A. and Bakker, W. (1989) Surf. Coat. Technol., 39/40, 53–64.
Miller, D.M. (1990) Simultaneous chromizing-aluminizing of an Fe-2.25 Cr-1 Mo steel and cobalt-base alloys by halide-activated pack cementation. Ph.D. dissertation, The Ohio State University.
Rapp, R.A., Wang, D. and Weisert, T. (1987) Simultaneous chromizing-aluminizing of iron and iron-base alloys by pack cementation, in High Temperature Coatings (eds M. Khobaib and R. Krutenat), The Metallurgical Society of AIME, pp. 131 –41.
Nash, P. (1986) The Ni-Cr System, in Binary Alloy Phase Diagrams (ed. T.B. Massalski) The American Society for Metals, p. 389.
Sun, W.P., Lin, T.H. and Hon, M.H. (1987) Metall. Trans. B, 18(9), 617–19.
Mazille, H.M. (1980) Thin Solid Films, 65, 67–74.
Felix, P.C. and Erdös, E. (1972) Werkstoffe und Korrosion, 23(8), 627–36.
Itzhak, D., Tuller, F.R. and Schieber, M. (1980) Thin Solid Films, 73, 379–84.
Smialek, J.L. (1974) Fused silicon-rich coatings for superalloys. NASA Technical Memorandum TM X-300I.
Fitzer, E. (1954) Archiv Eisenhüttenwesen, 25, 455.
Singleton, M.F., Murray, J.L. and Nash, P. (1986) The Ni-Al system, in Binary Alloy Phase Diagrams (ed. T.B. Massalski), The American Society for Metals, p. 141.
Grünling, H.W. and Bauer, R. (1982) Thin Solid Films, 95, 3–20.
Hoch, P. and Bren, J. (1969) Metalloberfläche, 23(1), 13–16.
Pennisi, FJ. and Gupta, D.K. (1981) Thin Solid Films, 84(1), 49–58.
Schneider, K, Bauer, R. and Grünling, H.W. (1978) Thin Solid Films, 54(3), 359–67.
Young, S.G. and Deadmore, D.L. (1980) Thin Solid Films, 73, 373–8.
Golightly, F.A. et al. (1976) Oxid. Metals, 10(3), 163–87.
Kumar, A., Nasrallah, M. and Douglass, D.L. (1974) Oxid. Metals, 8(4), 227–63.
Allam, I.M, Whittle, D.P. and Stringer, J. (1978) Oxid. Metals, 12(1), 35–66.
Tien, J.K. and Pettit, F.S. (1972) Metall. Trans., 3(6), 1587–99.
Whittle, D.P. and Stringer, J. (1980) Phil. Trans. R. Soc. Lond. A, 295, 309–29.
Jedlinski, J., Godlewski, K. and Mrowec, S. (1989) Mater. Sci. Engng, A121,539–43.
Fuhui, W., Hanyi, L., Linxiang, B. and Weitao, W. (1989) Mater. Sci. Engng, A121, 387–9.
Tu, D.C., Lin, C.C., Liao, S.J. and Chou, J.C. (1986) J. Vac. Sci. Technol., 4(6), 2601–8.
Bianco, R. and Rapp, R.A. (1990) Simultaneous chromizing-aluminizing of nickel-base superalloys with reactive element additions, in High Temperature Chemistry V (eds W.B. Johnson and R.A. Rapp), The Electrochemical Society, pp. 211–22.
LePrince, G., Alperine, S., Vandenbulcke, L. and Walder, A. (1989) Mater. Sci. Engng, A121, 419–25.
Wagner, C. (1965) Corr. Sci., 5(11), 751–64.
Galmiche, P. (1968) Metals and Materials, 2(7), 241–8.
Ravi, V.A., Choquet, P.A. and Rapp, R.A. (1988) Chromizing-aluminizing coating of Ni- and Fe-base alloys by the pack cementation technique, in Oxidation of High-Temperature Intermetallics (eds T. Grobstein and J. Doychak), The Metallurgical Society of AIME, pp. 127–45.
Walsh, P.N. (1973) Chemical aspects of pack cementation, in Proceedings of the 4th International Conference on Chemical Vapor Deposition (eds G.F. Wakefield and J.M. Blocher) The Electrochemical Society, pp. 147–68.
Fischer, T. (1992) Chromizing Arizona. Private communication, 11 Nov. 1992.
Levine, S.R. and Caves, R.M. (1974) J. Electrochem. Soc, 121(8), 1051–64.
Gupta, B.K., Sarkhel, A.K. and Seigle, L.L. (1976) Thin Solid Films, 39, 313–20.
Gupta, B.K. and Seigle, L.L. (1980) Thin Solid Films, 73, 365–71.
Pennisi, F.J., Kandasamy, N. and Seigle, L.L. (1981) Thin Solid Films, 84(1), 17–27.
Seigle, L.L. (1984) Thermodynamics and kinetics of pack cementation processes, in Surface Engineering (eds R. Kossowsky and S.C. Singhal), Applied Science Publishers, London, pp. 345–69.
Nciri, B. and Vandenbulcke, L. (1983) J. Less Common Metals, 95, 55–72.
Kung, S.C. and Rapp, R.A. (1988) J. Electrochem. Soc, 135(3), 731–41.
Kung, S.C. and Rapp, R.A., (1989) Oxid. Metals, 32(1/2), 89–109.
Restall, J.E. and Hayman, C. (1987) Process for diffusion coating metals. U.S. Patent 4,687,684.
Harper, M.A. and Rapp, R.A. (1991) Codeposition of chromium and silicon in diffusion coatings for iron-base alloys using pack cementation, in Surface Modification Technologies IV (eds T.S. Sudarshan, D.G. Bhat and M. Jeandin), The Metallurgical Society of AIME, pp. 415–28.
Johnson, W., Komarek, K. and Miller, E. (1968) Trans. Metall. Soc. AIME, 242, 1685–8.
Marijnessen G.H. (1983) Codeposition of chromium and aluminum during a pack process, in High- Temperature Protective Coatings (ed. S.C. Singhal), The Metallurgical Society of AIME, pp. 27–35.
Harper, M.A. and Rapp, R.A. (1991) Chromized/siliconized pack cementation diffusion coatings for heat-resistant alloys, in Proceedings of the First International Conference on Heat Resistant Materials (eds K. Natesan and D.J. Tillack), The American Society for Metals, pp. 379–86.
Flynn, H., Morris, A.E. and Carter, D. (1986) An interactive gas-phase removal version of SOLGASMIX, in Proceedings of the 25th CIM Conference of Metallurgists, TMS-CIM.
Bianco, R., Rapp, R.A. and Jacobson, N.S. (1992) Oxid. Metals, 38(1/2), 33–43.
Bianco, R., Harper, M.A. and Rapp, R.A. (1991) J. Metals, 43(11), 68–73.
Geib, F.D. and Rapp, R.A. (1993) Oxid. Metals, 40, 213–28.
Godlewska, E. and Godlewski, K. (1984) Oxid. Metals, 22(3/4), 117–31.
McCarron, R.L, Lindblad, N.R. and Chatterji, D. (1976) Corrosion, 32(12), 476–81.
Barrett, C.A. (1988) Oxid. Metals, 30(5/6), 361–90.
Jedlinski, J. and Mrowec, S. (1987) Mater. Sci. Engng, 87, 281–7.
Bianco, R. and Rapp, R.A. (1993) J. Electrochem. Soc, 140(4), 1181–90.
; Gale, W.F. and King, J.E. (1992) Metall. Trans. A, 23(9), 2657–65.
Bianco, R., Rapp, R.A. and Smialek, J.L. (1993) J. Electrochem. Soc, 140(4), 1191–1203.
DeVan, J.H. (1988) Oxidation behavior of Fe3Al and derivative alloys, in Oxidation of High-Temperature Intermetallics (eds T. Grobstein and J. Doychak), The Metallurgical Society of AIME, pp. 107–15.
Geib, F.D. and Rapp, R.A. (1992) Diffusion coatings for iron aluminide Fe3Al via halide-activated pack cementation, in Processing and Manufacturing of Advanced Materials for High-Temperature Applications (eds T.S. Srivatsan and V.A. Ravi), The Metallurgical Society of AIME, pp. 347–60.
Liu, CT., Lee, E.H. and McKamey, CG. (1990) Scripta Metall, 23(6), 875–80.
Smialek, J.L, Doychak, J. and Gaydosh, DJ. (1990) Oxid. Metals, 34(3/4), 259–75.
Subrahmanyan, J. (1988) J. Mater. Sci., 23(6), 1906–10.
Mabuchi, H., Asai, T. and Nakayama, Y. (1989) Scripta Metall., 23(4), 685–9.
Kung, S.C (1990) Oxid. Metals, 34(3/4), 217–28.
Smialek, J.L., Gedwill, M.A. and Brindley, P.K. (1990) Scripta Metall., 24,1291–96.
Christi, W., Rahmel, A. and Schutze, M. (1989) Oxid. Metals, 31(1/2), 1–34.
Natesan, K. and Park, J.H. (1989) Role of alloying additions in the oxida¬tion-sulfidation of Fe-base alloys, in Corrosion & Particle Erosion at High Temperatures (eds V. Srinivasan and K. Vedula), The Metallurgical Society of AIME, pp. 49–64.
Harper, M.A. (1992) Codeposition of chromium and silicon onto iron-base alloys via pack cementation. Ph.D. dissertation, The Ohio State University.
Felton, E.J. (1961) J. Electrochem. Soc, 108(6), 490–5.
Francis, J.M. and Whitlow, W.H. (1965) Corr. Sci., 5(10), 701–10.
Tedmon, CS, Jr. (1967) J. Electrochem. Soc, 113(8), 788–95.
Wood, G.C. and Whittle, D.P. (1967) Corr. Sci., 7(11), 763–82.
Perkins, R.A. and Meier, G.H. (1990) J. Metals, 42(8), 17–21.
Mueller, A.J, Wang, G, Rapp, R.A. and Courtright, E.L. (1992) J. Electrochem. Soc, 139(5), 1266–75.
Schlicting, J. and Neumann, S. (1982) J. Non-Cryst. Solids, 48(1), 185–94.
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 1996 Chapman & Hall
About this chapter
Cite this chapter
Bianco, R., Rapp, R.A. (1996). Pack cementation diffusion coatings. In: Stern, K.H. (eds) Metallurgical and Ceramic Protective Coatings. Springer, Dordrecht. https://doi.org/10.1007/978-94-009-1501-5_9
Download citation
DOI: https://doi.org/10.1007/978-94-009-1501-5_9
Publisher Name: Springer, Dordrecht
Print ISBN: 978-94-010-7171-0
Online ISBN: 978-94-009-1501-5
eBook Packages: Springer Book Archive