Effect of alumina dispersion on oxidation behavior as well as friction and wear behavior of HVOF-sprayed CoCrAlYTaCSi coating at elevated temperature up to 1000 °C

Abstract CoCrAlYTaCSi alloy coating and CoCrAlYTaCSi Al 2 O 3 composite coating were prepared on Inconel 718 alloy substrate by high velocity oxy-fuel (HVOF) spraying in order to avoid the failure of the hot parts made of the Ni-based alloy induced by oxidation and wear damage at elevated temperature of up to 1000 °C, with which the agglomerated powder of CoCrAlYTaCSi and Al 2 O 3 was sintered to afford the to-be-sprayed CoCrAlYTaCSi Al 2 O 3 powder. The microstructure and phase composition of the as-sprayed coatings were analyzed by scanning electron microscopy, transmission electron microscopy and X-ray diffraction, and their mechanical properties were determined with a Vicker’s hardness tester and a nano-indentation tester. Furthermore, the oxidation behavior of the coatings was evaluated by thermogravimetry and oxidation test in muffle furnace, and their friction and wear behavior under dry sliding against Si 3 N 4 ball from room temperature to 1000 °C was evaluated with a high temperature tribometer. Results show that Ta, C and Si elements mainly exist in the forms of TaC and SiC nano-particles in as-sprayed coatings. The incorporation of Al 2 O 3 dispersion results in a significant increase in the hardness, modulus, contact stiffness and wear resistance, but metallic Co and Cr slightly reduce the oxidation resistance of CoCrAlYTaCSi coating. Particularly, as-fabricated CoCrAlYTaCSi Al 2 O 3 coating exhibits much better wear resistance than CoCrAlYTaCSi coating and other MCrAlY/oxide metal-matrix coatings prepared by HVOF or other technologies, showing promising potential as a protective coating of Ni-alloy based hot parts.

[1]  Yoshiyasu Itoh,et al.  Characteristics of MCrAlY Coatings Sprayed by High Velocity Oxygen-Fuel Spraying System , 2000 .

[2]  Y. Liang,et al.  Improved oxidation resistance of NiCrAlY coatings , 2003 .

[3]  Margaret M. Hyland,et al.  Microhardness variation in relation to carbide development in heat treated Cr3C2–NiCr thermal spray coatings , 2003 .

[4]  Edson Costa Santos,et al.  Structure of NiCrAlY coatings deposited on single-crystal alloy turbine blade material by laser cladding , 2009 .

[5]  S. Javadpour,et al.  Hot corrosion of nanostructured CoNiCrAlYSi coatings deposited by high velocity oxy fuel process , 2014 .

[6]  J. Kang,et al.  Surface properties and tensile bond strength of HVOF thermal spray coatings of WC-Co powder onto the surface of 420J2 steel and the bond coats of Ni, NiCr, and Ni/NiCr☆ , 2009 .

[7]  Fu-hui Wang,et al.  Preparation and oxidation behaviour of nanocrystalline Ni + CrAlYSiN composite coating with AlN diffusion barrier on Ni-based superalloy K417 , 2012 .

[8]  Lidong Zhao,et al.  High velocity oxy-fuel spraying of a NiCoCrAlY and an intermetallic NiAlTaCr alloy , 2002 .

[9]  S. Prakash,et al.  Hot corrosion behaviour of HVOF-sprayed NiCrBSi coatings on Ni- and Fe-based superalloys in Na2SO4–60% V2O5 environment at 900 °C , 2006 .

[10]  Hui-di Zhou,et al.  Microstructure and high-temperature friction and wear behavior of WC-(W,Cr)2C-Ni coating prepared by high velocity oxy-fuel spraying , 2011 .

[11]  P. H. Shipway,et al.  The effect of temperature on wear and friction of a high strength steel in fretting , 2013 .

[12]  C. Zhang,et al.  Pitting initiation in Fe-based amorphous coatings , 2012 .

[13]  Hui-di Zhou,et al.  Composition versus friction and wear behavior of plasma sprayed WC–(W,Cr)2C–Ni/Ag/BaF2–CaF2 self-lubricating composite coatings for use up to 600 °C , 2012 .

[14]  M. Shamanian,et al.  Microstructural and morphological evaluation of MCrAlY/YSZ composite produced by mechanical alloying method , 2012 .

[15]  J. Chen,et al.  Effect of heat treatment on wear behaviour of WC–(W,Cr)2C–Ni coating , 2012 .

[16]  Ann Bolcavage,et al.  Technical and Economical Aspects of Current Thermal Barrier Coating Systems for Gas Turbine Engines by Thermal Spray and EBPVD: A Review , 2008 .

[17]  Zhen-hua Chen,et al.  Performance of abrasive wear of WC-12Co coatings sprayed by HVOF , 2009 .

[18]  Claudio V. Di Leo,et al.  A new methodology for characterizing traction-separation relations for interfacial delamination of thermal barrier coatings , 2014 .

[19]  J. Florek,et al.  Consideration of Lubricants for Temperatures above 1000 F , 1959 .

[20]  J. Guilemany,et al.  Cold Spray Deposition of a WC-25Co Cermet onto Al7075-T6 and Carbon Steel Substrates , 2014, International Thermal Spray Conference.

[21]  E. Jordan,et al.  Thermal Barrier Coatings for Gas-Turbine Engine Applications , 2002, Science.

[22]  J. Aoh,et al.  On the wear characteristics of cobalt-based hardfacing layer after thermal fatigue and oxidation , 2001 .

[23]  S. Leen,et al.  Residual stresses in high-velocity oxy-fuel thermally sprayed coatings – Modelling the effect of particle velocity and temperature during the spraying process , 2007 .

[24]  Thomas Alan Taylor,et al.  Development of alloyed and dispersion-strengthened MCrAlY coatings , 1996 .

[25]  P. K. Datta,et al.  Studies of high temperature sliding wear of metallic dissimilar interfaces , 2005 .

[26]  S. Aksoy,et al.  Friction and Wear Characteristics of Haynes 25, 188, and 214 Superalloys Against Hastelloy X up to 540 °C , 2012, Tribology Letters.

[27]  J. Guilemany,et al.  Study of the high temperature oxidation performance of Thermal Barrier Coatings with HVOF sprayed bond coat and incorporating a PVD ceramic interlayer , 2012 .

[28]  P. H. Shipway,et al.  Microstructural evolution in thermally sprayed WC-Co coatings: Comparison between nanocomposite and conventional starting powders , 2000 .

[29]  B. James,et al.  The role of microstructure in the high temperature oxidation mechanism of Cr3C2–NiCr composite coatings , 2009 .

[30]  K. Bobzin,et al.  Development of Oxide Dispersion Strengthened MCrAlY Coatings , 2008, International Thermal Spray Conference.

[31]  C. Ponton,et al.  Investigation into the wear behaviour of Tribaloy 400C during rotation as an unlubricated bearing at 600 °C , 2010 .

[32]  Hong Yu Wang,et al.  High temperature frictional wear behaviors of nano-particle reinforced NiCoCrAlY cladded coatings , 2011 .

[33]  M. S. Li.  Friction of alloys at high temperature , 2009 .

[34]  H. Du,et al.  Microscopy of glazed layers formed during high temperature sliding wear at 750 °C , 2003 .

[35]  P. K. Datta,et al.  Studies of high temperature sliding wear of metallic dissimilar interfaces II: Incoloy MA956 versus Stellite 6 , 2006 .

[36]  P. Poza,et al.  TEM analysis of the microstructure of thermal barrier coatings after isothermal oxidation , 2012 .

[37]  Lidong Zhao,et al.  Wear behaviour of Al2O3 dispersion strengthened MCrAlY coating , 2004 .

[38]  C. Ponton,et al.  Investigation into the wear behaviour of Stellite 6 during rotation as an unlubricated bearing at 600 °C , 2011 .

[39]  H. S. Sidhu,et al.  High temperature hot corrosion behaviour of NiCr and Cr3C2–NiCr coatings on T91 boiler steel in an aggressive environment at 750 °C , 2012 .

[40]  H. Mandal,et al.  Wear performance of spark plasma sintered Co/WC and cBN/Co/WC composites , 2014 .

[41]  Lidong Zhao,et al.  HVOF spraying of Al2O3-dispersion-strengthened NiCr powders , 2004 .