It has been demonstrated that NiAl high-temperature protective coatings have the capacity to enhance the surface temperature tolerance of materials utilized in the hot-section components of aero-engines to a considerable extent. Among these, Hf-modified NiAl coatings have been shown to enhance oxidation resistance and extend the service life of the coatings. Nevertheless, the enhancement of oxidation resistance achieved through the doping of a single rare earth element remains constrained. The present study investigated the influence of Y doping on the microstructural evolution and oxidation resistance of NiAlHf coatings at 1 150 ℃. The NiAlHf/Y coatings were deposited on cylindrical nickel-based single-crystal superalloy samples with a diameter of 16 mm and thickness of 2 mm using the arc ion plating (AIP) technique. The as-deposited samples were then subject to isothermal annealing at 900 ℃ and 5×10-2 Pa for a duration of 4 h. This was followed by isothermal oxidation experiments at 1 150 ℃ for 200 h. The phase composition of the oxide layers was analyzed by XRD, while the surface and cross-sectional morphologies and elemental distribution of the coatings were systematically characterized with a SEM equipped with an EDS. The results showed that, in the early stages of oxidation, a large number of radioactive cracks appear on the surface of the NiAlHf coating. In contrast, the NiAlHfY coating formed a more continuous, flat Al2O3 layer. This difference was due to the fact that Hf and Y co-doping could slow down the transformation of θ-Al2O3 to α-Al2O3, thereby reducing stresses in the oxidized layer. In NiAlHf coatings, HfO2 was primarily found at the oxide/coating interface and within the coating. In contrast, in NiAlHfY coatings, HfO2 was predominantly present in the oxide layer and distributed along the Al2O3 grain boundaries. Meanwhile, Y was uniformly distributed within the oxide layer, with Y bias observed in the interdiffusion zone at the coating/substrate interface. Analysis of the oxidation dynamic curve showed that the oxidation weight gain of the two coatings followed a parabolic trend when the oxidation duration was less than 75 h and a linear trend when it was greater than 75 h. It also revealed the presence of a multilayered structure consisting of mixed oxides, such as Al2O3, NiAl2O4 and NiO, with a higher concentration of refractory elemental oxides in the oxidized layer. Furthermore, the NiAlHf coating exhibited an average oxidation rate of 0.122 34 g/(m2·h) at 1 150 ℃ for 200 h, while the NiAlHfY coating showed a lower rate of 0.113 88 g/(m2·h). Moreover, the β-NiAl phase consumption was found to be slower in the NiAlHfY coating, thus demonstrating its superior protective capability for the substrate. In conclusion, the presence of Y in NiAlHf coating has a further reducing effect on the growth rate of the oxide layer. In addition, the adhesion of the coating is improved, and the antioxidant properties are made more effective. These findings provide a solid foundation for the further development and industrial application of the future high-temperature protective coating system.
Key words
NiAlHf coating /
NiAlHfY coating /
reactive element doping /
microstructural evolution /
high-temperature oxidation resistance
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Funding
The National Natural Science Foundation of China (52401115)
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