1. Oxidation behaviour and thermal cycling response of HVAF and HVA(O)F NiCoCrAlY coatings.
- Author
-
Majumder, Sukanya, Sivakumar, G., Jayaram, Vikram, and Srinivasan, Dheepa
- Subjects
- *
MIXING height (Atmospheric chemistry) , *GAS turbines , *HEAT treatment , *ISOTHERMAL processes , *SUBSTRATES (Materials science) , *METAL spraying - Abstract
The isothermal and thermal cyclic oxidation behaviour of NiCoCrAlY coatings sprayed using high-velocity air fuel (HVAF) and high-velocity air (oxy) fuel (HVA(O)F) processes was compared at 1100 °C and 1120 °C on Ni-based superalloy substrates. The evolution of the NiAl (β) phase and thermally grown oxide (TGO) was systematically analysed as a function of time, up to 100 h. The TGO grew from 2 to 3 μm (after 20 h) to nearly 25 μm after 40 h and comprised a mixed oxide layer of α-Al2O3 and NiO after 40 h under isothermal oxidation. The Al content in the coating mid-zone remains unchanged at 8–10 wt%, however, the Al content in the β-depleted zone underneath the TGO drops to < 2 wt%, leading to a fully γ microstructure after 50 h of isothermal exposure. The β-depleted layer thickness increases with exposure time from 5 μm after 20 h to nearly 45 μm after 40 h. The key difference between HVAF and HVA(O)F coatings could be seen in the development, after isothermal exposure, of porosity in the case of HVAF, while the HVA(O)F remained dense. Thermal cyclic exposure after 20 h between room temperature and 1100 °C led to coating delamination in the case of HVAF coating, whereas HVA(O)F coatings remained intact. The delamination is attributed to the formation of pores in the vicinity of the grits. Overall, there seems little difference in the oxidation properties of the coatings between the two processes under isothermal exposure, whereas HVA(O)F shows better structural integrity after thermal cycling. The results in this manuscript are the first to show the behaviour of HVAF-based coating response to high-temperature heat treatment and the analysis thereof to look at the novel aspect of interchangeability of using these coatings for various high-temperature oxidation applications such as in gas turbines components. [ABSTRACT FROM AUTHOR]
- Published
- 2025
- Full Text
- View/download PDF