Today is Email Alert  RSS

Research Progress on High-Temperature Oxidation and Corrosion Mechanisms of Aluminide Coatings

Expand
  • (State Key Laboratory for Mechanical Behavior of Materials, Xi’an Jiaotong University, Xi’an 710049, China)

Received date: 2023-03-25

  Revised date: 2023-04-12

  Accepted date: 2023-05-20

  Online published: 2023-10-15

Supported by

国家重点研发计划(2020YFB2010403)资助

Abstract

Aluminide coatings are widely used to protect engine hot-section components such as turbine blades, but during service, they are prone to high-temperature oxidation and hot corrosion,resulting in failure.Aiming at the failure of aluminide coatings in high-temperature environments during service, the mechanism of high-temperature oxidation and hot corrosion of aluminide coating was introduced.Factors affecting high-temperature oxidation and hot corrosion of aluminide coatings, as well as methods for improving the oxidation resistance and corrosion resistance of aluminide coatings, including the addition of modified elements such as Cr, Si, Pt and active elements, and pre-oxidation treatment, were described.Finally, the future of high-temperature oxidation and hot corrosion research of aluminide coatings was prospected.

Cite this article

XIE Yuhao, QI Haoxiong, MA Rui, MENG Guohui, LIU Meijun, YANG Guanjun . Research Progress on High-Temperature Oxidation and Corrosion Mechanisms of Aluminide Coatings[J]. Materials Protection, 2023 , 56(10) : 166 -181 . DOI: 10.16577/j.issn.1001-1560.2023.0248

References

[1] 蒋成洋, 丰 敏, 陈明辉, 等.简单/改性铝化物涂层的研究现状[J].表面技术, 2021, 50(9):33-42.JIANG C Y, FENG M, CHEN M H, et al.Current research status of simple/modified aluminide coatings[J].Surface Technology, 2021, 50(9):33-42.

[2] 董 宇,刘梅军,徐 彤,等.航空发动机压气机防钛火可磨耗封严涂层的研究进展[J].材料保护, 2021, 54(11):129-139.DONG Y, LIU M J, XU T, et al.Research progress on titanium-fire retardant abradable seal coatings for compressor in aero- engine[J].Materials Protection, 2021, 54(11):129-139.

[3] 任 鑫.几种高温防护涂层的高温氧化和热腐蚀行为研究[D].南京:南京理工大学, 2005.REN X.High-temperature oxidation and hot corrosion behaviors of several high-temperature protective coatings[D].Nanjing: Nanjing University of Science and Technology,2005.

[4] 齐浩雄,马 瑞,孟国辉,等.高温叶片用渗铝涂层的研究进展[J].材料保护, 2022, 55(10):147-161.QI H X, MA R, MENG G H, et al.Research progress on aluminized coatings for high temperature blades[J].Materials Protection, 2022, 55(10):147-161.

[5] 刘培生.铝化物高温防护涂层的现状[J].稀有金属材料与工程, 2003(9): 681-685.LIU P S.Status of study on high-temperature oxidation law for aluminide coatings[J].Rare Metal Materials and Engineering, 2003(9): 681-685.

[6] 张忠礼.含Al 热喷涂涂层的高温表现与Al 扩散机制[D].沈阳:沈阳工业大学, 2007.ZHANG Z L.High temperature behaviors and aluminum diffusing mechanism of containing aluminum coatings produced by thermal spray[D].Shenyang: Shenyang University of Technology, 2007.

[7] WANG G, GLEESON B, DOUGLASS D L.An extension of Wagner’s analysis of competing scale formation[J].Oxidation of Metals, 1991, 35(3): 317-332.

[8] 马利影.铝化物涂层体系氧化物扩散障的内生机制研究[D].上海:上海工程技术大学, 2016.MA L Y.Study on the endogenous mechanism of oxide diffusion barrier in the aluminide coating system[D].Shanghai:Shanghai University of Engineering Science, 2016.

[9] LI C, XU X J, WANG S F, et al.High-temperature oxidation and hot corrosion behavior of the Cr-modified aluminide coating obtained by a thermal diffusion process[J].Materials Research Express, 2019, 6(8): 086444.

[10] BRUMM M,GRABKE H.The oxidation behaviour of NiAl-I.Phase transformations in the alumina scale during oxidation of NiAl and NiAl-Cr alloys[J].Corrosion Science, 1992,33(11): 1 677-1 690.

[11] ZHOU Z, GUO H, ABBAS M, et al.Effect of water vapor on the phase transformation of alumina grown on NiAl at 950℃[J].Corrosion Science, 2011, 53(9): 2 943-2 947.

[12] PARK S J, SEO S M, YOO Y S, et al.Effects of Cr, W,and Mo on the high temperature oxidation of Ni-based superalloys[J].Materials, 2019, 12(18): 2934.

[13] ABU-WARDA N, López A J, López M D, et al.High temperature corrosion and wear behavior of HVOF-sprayed coating of Al2 O3-NiAl on AISI 304 stainless steel[J].Surface and Coatings Technology, 2019, 359: 35-46.

[14] YU X, SONG P, HE X, et al.Influence of the combinedeffect of NaCl and Na2SO4 on the hot corrosion behaviour of aluminide coating on Ni-based alloys[J].Journal of Alloys and Compounds, 2019, 790: 228-239.

[15] WANG Q, ZHOU D, YU M, et al.Oxidation and hot corrosion behaviors of Mo-doped NiMoAlY alloys at 750 ℃[J].Corrosion Science, 2022, 201: 110262.

[16] 李 伟.Re 改性铝化物涂层的制备和氧化行为研究[D].合肥:中国科学技术大学, 2021.LI W.Preparation and oxidation behaviors of Rhenium doped aluminide coatings[D].Hefei: University of Science and Technology of China, 2021.

[17] GOWARD G W, BOONE D H.Mechanisms of formation of diffusion aluminide coatings on nickel-base superalloys[J].Oxidation of Metals, 1971, 3(5): 475-495.

[18] LIU G, LI M, ZHU M, et al.Transient of alumina oxide scale on β-NiAl coated on M38G alloy at 950 ℃[J].Intermetallics, 2007, 15(10): 1 285-1 290.

[19] SLOOF W G.Self healing in coatings at high temperatures[M].[S.l.]: Springer, 2007: 309-321.

[20] 管恒荣, 楼翰一, 毛晓禹, 等.两种高温合金渗Al 防护层的退化过程[J].金属学报, 1981(4): 412-417.GUAN H R, LOU H Y, MAO X Y, et al.Deterioration of aluminide coating on Nickel-base superalloys[J].Acta Metallurgica Sinica, 1981(4): 412-417.

[21] 刘 贺, 杨尔其, 王蕴欢.CMSX-4 单晶合金上铂铝涂层制备及高温氧化性能评价[J].辽宁化工, 2022, 51(3):325-328.LIU H, YANG E Q, WANG Y H.Preparation and high temperature oxidation performance of Platinum - aluminum coating on CMSX-4 single crystal superalloy[J].Liaoning Chemical Industry, 2022, 51(3): 325-328.

[22] DOYCHAK J, SMIALEK J, MITCHELL T.Transient oxidation of single-crystal β-NiAl[J].Metallurgical Transactions A, 1989, 20(3): 499-518.

[23] YAN K, GUO H, GONG S.High-temperature oxidation behavior of minor Hf doped NiAl alloy in dry and humid atmospheres[J].Corrosion Science, 2013, 75: 337-344.

[24] LIU Q, QIN H, BOSCOBOINIK J A, et al.Comparative study of the oxidation of NiAl (100) by molecular oxygen and water vapor using ambient-pressure X-ray photoelectron spectroscopy[J].Langmuir, 2016, 32(44): 11 414-11 421.

[25] WASIELEWSHI G E, RAPP R A.Superalloys[M].New York: Wiley, 1972.

[26] PARK S J, SEO S M, YOO Y S, et al.Effects of Al and Ta on the high temperature oxidation of Ni-based superalloys[J].Corrosion Science, 2015, 90: 305-312.

[27] QIN L, PEI Y, LI S, et al.Role of volatilization of molybdenum oxides during the cyclic oxidation of high-Mo containing Ni-based single crystal superalloys[J].Corrosion Science, 2017, 129: 192-204.

[28] RAPP R A, ZHANG Y S.Hot corrosion of materials: fundamental studies [J].The Journal of The Minerals,Metals & Materials Society, 1994, 46(12): 47-55.

[29] 张 磊, 吴 勇, 夏思瑶, 等.CVD 法Pt 改性铝化物涂层的制备及其热腐蚀行为研究[J].材料保护, 2020, 53(3):1-7.ZHANG L, WU Y, XIA S Y, et al.Hot Corrosion Behavior of Platinum Modified Aluminide Coatings Deposited by Chemical Vapor Deposition Method[J].Materials Protection, 2020, 53(3):1-7.

[30] 阳颖飞.Pt 改性铝化物涂层的制备科学及性能研究[D].合肥:中国科学技术大学, 2017.YANG Y F.Preparation and performance investigation of Ptmodified aluminide coatings[D].Hefei: University of Science and Technology of China, 2017.

[31] SHIRVANI K,RASHIDGHAMAT A.Evolution of oxide scale on aluminide and Pt-aluminide coatings exposed to type I(870 ℃) hot corrosion[J].Oxidation of Metals, 2016, 85(1): 75-85.

[32] ABU-WARDA N, López A J, López M D, et al.High temperature corrosion and wear behavior of HVOF-sprayed coating of Al2 O3-NiAl on AISI 304 stainless steel[J].Surface and Coatings Technology, 2019, 359: 35-46.

[33] WANG Y P, RISHI P, ELENA Y, et al.Role of temperature in Na2SO4-K2SO4 deposit induced type II hot corrosion of NiAl coating on a commercial Ni-based superalloy[J].Advanced Engineering Materials, 2020, 22(6): 1901244.

[34] LEYENS C, WRIGHT I, PINT B.Effect of experimental procedures on the cyclic, hot-corrosion behavior of NiCo-CrAlY-type bondcoat alloys[J].Oxidation of Metals,2000,54(3): 255-276.

[35] 楼翰一,白林祥,王福会,等.熔盐成份对高温合金渗铝和渗铬层抗热腐蚀性能的影响[J].中国腐蚀与防护学报, 1989, 9(2): 95-102.LOU H Y, BAI L X, WANG F H, et al.Effect of chemistry of molten salts on hot-corrosion resistance of aluminized and Chromized coatings on superalloys[J].Journal of Chinese Society for Corrosion and Protection, 1989(2): 95-102.

[36] RAPP R A.Chemistry and electrochemistry of hot corrosion of metals[J].Materials Science and Engineering, 1987,87: 319-327.

[37] 宁礼奎,郑 志,谭 毅,等.一种新型定向凝固镍基高温合金抗热腐蚀性能的研究[J].金属学报, 2009, 45(2): 161-166.NING L K, ZHENG Z, TAN Y, et al.Study on hot corrosion resistance of a new directional solidification ni-based superalloy[J].Acta Metallurgica Sinica, 2009, 45(2):161-166.

[38] PETTIT F.Hot corrosion of metals and alloys[J].Oxidation of Metals, 2011, 76(1): 1-21.

[39] CHOQUET P,NAYLOR E,RAPP R A.Simultaneous chromizing and aluminizing of iron-base alloys[J].Materials Science and Engineering: A, 1989, 120: 413-418.

[40] 褚虎儿, 曹铁梁, 石声泰.铬铝涂层及其抗高温腐蚀的行为[J].中国腐蚀与防护学报, 1987(2): 77-82.ZHU H E, CAO T L, SHI S T.Co-deposition of Cr and Al by pack cementation and the resistance of such coatings against oxidation and hot corrosion[J].Journal of Chinese Society for Corrosion and Protection, 1987(2): 77-82.

[41] ROSADO C, Schütze M.Protective behaviour of newly developed coatings against metal dusting[J].Materials and Corrosion, 2003, 54(11): 831-853.

[42] DONG Z H, XIE Y, PENG X.Effect of Cr particle size on the development of a chromia scale on Ni-Cr composites[J].Corrosion Science, 2022, 194: 109915.

[43] 王福会.高温扩散型铝化物涂层[J].材料保护, 1992,25(8): 44-47.WANG F H.High-temperature diffusion aluminiferous oxides coating[J].Materials Protection, 1992(8):44-47.

[44] 都海良, 周佩德, 石声泰.含硫气氛中镍基合金上渗铝层的退化[J].中国腐蚀与防护学报, 1987, 7(3):171-176.DU H L, ZHOU P D, SHI S T.Degradation of aluminide coatings on Ni-base alloys in Sulfur-containing atmosphere[J].Journal of Chinese Society for Corrosion and Protection, 1987(3): 171-176.

[45] KIRCHER T, MCMORDIE B, MCCARTER A.Performance of a silicon-modified aluminide coating in high temperature hot corrosion test conditions[J].Surface and Coatings Technology, 1994, 68: 32-37.

[46] 蔡玉林, 郑运荣, 莫龙生, 等.Al-Si 涂层中硅的分布及作用—含Si 隔层的研究[J].航空材料, 1981(增刊1):39-44.CAI Y L, ZHENG Y R, MO L S, et al.The distribution and effect of Silicon in Al-Si coatings - on investigation of Si-containing barrier[J].Journal of Aeronautical Materials,1981(S1): 39-44.

[47] 杨世伟, 王俊一.DZ4 合金渗Al-Si 涂层抗高温氧化机理研究[J].哈尔滨工程大学学报, 2008, 29(9): 997-1 000.YANG S W, WANG J Y.High temperature oxidation properties of Al-Si coatings on a DZ4 superalloy[J].Journal of Harbin Engineering University, 2008, 29(9): 997-1 000.

[48] 杨忠林,莫龙生,蔡玉林,等.铝—硅涂层防护性能的研究[J].中国腐蚀与防护学报, 1981(4): 28-37.YANG Z L, MO L S, CAI Y L, et al.High temperature performance of the aluminium - silicon coatings[J].Journal of Chinese Society for Corrosion and Protection, 1981(4):28-37.

[49] 肖绪昌, 吴凤筠, 杨忠林, 等.铸造镍基合金K-3 的热腐蚀及防护研究[J].中国腐蚀与防护学报, 1983(3):168-176.XIAO C X, WU F J, et al.Hot corrosion and protection of cast Nickel-base superalloy K-3 for gas turbine[J].Journal of Chinese Society for Corrosion and Protection, 1983(3):168-176.

[50] CHEN M Y, FENG K L, LI M F, et al.Hot corrosion behaviour of Al-Si-Dy coating on new γ′-strengthened cobaltbased alloy[J].Corrosion Science, 2020, 166: 108431.

[51] FOUNTAIN J, GOLIGHTLY F, STOTT F, et al.The influence of platinum on the maintenance of α-Al2O3 as a protective scale [J].Oxidation of Metals, 1976, 10 (5):341-345.

[52] ALLAM I, AKUEZUE H, WHITTLE D.Influence of small Pt additions on Al2 O3 scale adherence[J].Oxidation of Metals, 1980, 14(6): 517-530.

[53] SVENSSON H, CHRISTENSEN M, KNUTSSON P, et al.Influence of Pt on the metal-oxide interface during high temperature oxidation of NiAl bulk materials[J].Corrosion Science, 2009, 51(3): 539-546.

[54] HOU P Y, TOLPYGO V.Examination of the platinum effect on the oxidation behavior of nickel-aluminide coatings[J].Surface and Coatings Technology, 2007, 202 (4-7):623-627.

[55] NIU Y, WU W, BOONE D, et al.Oxidation behaviour of simple and Pt - modified aluminide coatings on IN738 at 1 100 ℃[J].Le Journal de Physique IV, 1993, 3(C9):C9-511-C9-9.

[56] 王 迪, 王 栋, 谢 光, 等.Pt-Al 涂层对一种镍基单晶高温合金抗热腐蚀行为的影响[J].金属学报, 2021,57(6):780-790.WANG D, WANG D, XIE G, et al.Influence of Pt-Al coating on hot corrosion resistance behaviors of a Ni-based single- crystal superalloy[J].Acta Metallurgica Sinica,2021, 57(6):780-790.

[57] PINT B A.Optimization of reactive-element additions to improve oxidation performance of alumina-forming alloys[J].Journal of the American Ceramic Society, 2003, 86(4):686-695.

[58] PINT B A, HAYNES J A, BESMANN T M.Effect of Hf and Y alloy additions on aluminide coating performance[J].Surface and Coatings Technology, 2010, 204(20): 3 287-3 293.

[59] WHITTLE D, STRINGER J.Improvements in high temperature oxidation resistance by additions of reactive elements or oxide dispersions[J].Philosophical Transactions of the Royal Society of London Series A, Mathematical and Physical Sciences, 1980, 295(1 413): 309-329.

[60] PINT B, LEIBOWITZ J, DEVAN J.The effect of an oxide dispersion on the critical Al content in Fe-Al alloys[J].Oxidation of Metals, 1999, 51(1): 181-197.

[61] PINT B, GARRATT-REED A, HOBBS L.The reactive element effect in commercial ODS FeCrAI alloys[J].Materials at High Temperatures, 1995, 13(1): 3-16.

[62] MARINO K A, HINNEMANN B, CARTER E A.Atomicscale insight and design principles for turbine engine thermal barrier coatings from theory[J].Proceedings of the National Academy of Sciences, 2011, 108(14): 5 480-5 487.

[63] SUN W Y, WANG J L, YANG L L, et al.Studies on corrosion behavior of a single-crystal superalloy and its sputtered nanocrystalline coatings with solid NaCl deposit in O2+38%H2O environment at 700 ℃[J].Corrosion Science, 2022,161: 108187.

[64] PINT B A.The role of chemical composition on the oxidation performance of aluminide coatings[J].Surface and Coatings Technology, 2004, 188: 71-78.

[65] PINT B.Experimental observations in support of the dynamic-segregation theory to explain the reactive-element effect[J].Oxidation of Metals, 1996, 45(1): 1-37.

[66] HOU P.Segregation phenomena at thermally grown Al2 O3/alloy interfaces[J].Annual Review of Materials Research,2008, 38: 275-298.

[67] 德先龙, 邓 鹏, 尹 斌, 等.Co/Pt 改性铝化物涂层热腐蚀行为探究及比较[J].材料研究与应用, 2022, 16(2):243-252.DE X L, DENG P, YIN B, et al.Study and comparison of the hot corrosion behavior of Co/Pt co-modified aluminide coating[J].Materials Research and Application, 2022, 16(2):243-252.

[68] LI S, XU M, ZHANG C, et al.Co-doping effect of Hf and Y on improving cyclic oxidation behavior of (Ni, Pt) Al coating at 1 150 ℃[J].Corrosion Science, 2021, 178:109093.

[69] MENG X, YUWEN P, SHAO W, et al.Cyclic oxidation behaviour of Co/Si co - doped β - NiAl coating on nickel based superalloys [J].Corrosion Science, 2018, 133:112-119.

[70] ADHARAPURAPU R R, ZHU J, DHEERADHADA V S,et al.Effective Hf-Pd Co-doped β-NiAl (Cr) coatings for single-crystal superalloys[J].Acta Materialia, 2014, 76:449-462.

[71] ZHOU Z, PENG H, ZHENG L, et al.Microstructure and cyclic oxidation behaviour of low-Pt/Dy co-doped β-NiAl coatings on single crystal (SC) superalloy[J].Surface and Coatings Technology, 2016, 304: 108-116.

[72] LI X, ZOU J, SHI Q, et al.Effect of Al2 O3 scales from pre-oxidation on the microstructural evolution and phase transition of NiAlHf coatings at 1 200 ℃[J].Surface and Coatings Technology, 2022, 433: 128119.

[73] TOLPYGO V K, CLARKE D R.The effect of oxidation pretreatment on the cyclic life of EB-PVD thermal barrier coatings with platinum-aluminide bond coats[J].Surface and Coatings Technology, 2005, 200(5/6): 1 276-1 281.

[74] LI Y Y, HUANG D, ZHANG C Y, et al.High-temperature corrosion behaviour of Pt-modified aluminide coating with solid NaCl deposit in O2+10 vol%H2O and the influence of pre-oxidation treatment[J].Corrosion Science, 2022, 204:110421.

[75] LI Q, ZHANG D, SONG P, et al.Influence of pre-oxidation on high temperature oxidation and corrosion behavior of Ni-based aluminide coating in Na2SO4 salt at 1 050 ℃[J].Frontiers in Materials, 2021: 189.

[76] YANG Y F, JIANG C Y, ZHANG Z Y, et al.Hot corrosion behaviour of single-phase platinum-modified aluminide coatings: Effect of Pt content and pre-oxidation[J].Corrosion Science, 2017, 127: 82-90.

[77] GARCIA -HERRERA J E, Espinosa-arbeláez D G,Cáceres-díaz L A, et al.Effect of pre-oxidation treatments on the structural, microstructural, and chemical properties of β-(Ni, Pt) Al system[J].Surface and Coatings Technology, 2019, 367: 156-164.

Outlines

/