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Research of Materials Science

June 2014, Volume 3, Issue 2, PP.30-35

Hot Corrosion Behaviors of Four Coatings on


Ni-Based Superalloy
Duoli Wu#, Hongyu Zhang, Hua Wei, Qi Zheng, Tao Jin, Xiaofeng Sun
Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, P. R. China

Abstract
In order to study hot corrosion behaviors of the high temperature protective coatings on the superalloy, four modified aluminide
coatings (NiCr-CrAl coating, Co-Al coating, Al-Si coating and Al-Ti coating) were prepared on the surface of a Ni-based
superalloy. The microstructures and the hot corrosion behaviors in the salt of 25 wt. % NaCl + 75 wt. % Na 2SO4 at 900 were
investigated. The results show that a large amount of mixed oxides include Cr2O3, -Al2O3 and NiCr2O4 spinel have been formed
on the surface of four coatings except for the NiCr-CrAl coating. The oxides can enhance the hot corrosion resistance of the
coatings. Different morphologies appeared on the surface of the four coatings after corrosion for 100 h at 900 . Obviously,
discontinuous corrosion products and localized scaling zones occurred on the surface of the NiCr-CrAl coating. The Co-Al
coatings were continuous and dense relatively after hot corrosion. However, obvious crack appeared on the surface, which can
lead to great degradation and even failure of the coating. As for the Al-Si coating, not only the cracks and spalling arose on the
surface, but also the internal oxidation were found in the substrate. The Ti - Al coating were continuously compact and adhered
tightly to the substrate after corrosion. Obviously, the Ti-Al coating provided much better protection to the alloy than the other
three coatings in this kind of mixed salt.
Keywords: Superalloy, Modified Aluminide Coatings, Hot Corrosion

110016

NiCr-CrAlCo-AlAl-Si

Al-Ti 4 900 25wt. % NaCl+75wt. % Na2SO4


NiCr-CrAl Cr2O3-Al2O3
NiCr2O4 900 100 h NiCr-CrAl
; Co-Al Al-Si
Ti-Al

1600 1000-1200
[1-4]

51371173
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[5,6]

[7-11]
20 50 60 [12-14]
-NiAl -CoAl
Al2O3
[15]
CrSiTiCoPt [16,17]

NiCr-CrAlCo-AlAl-Si Al-Ti

1
1
1
Material

Cr

Co

Mo

Nb

Ta

Al

Ti

(mass fraction, %)
B
Ni

Substrate

0.15

16.0

8.5

2.6

1.85

0.85

1.85

3.5

3.3

0.009

Bal.

15 mm2.5 mm
800 SiC
15 min
NiCr-CrAlCo-AlAl-Si Al-Ti
2 30-40 m
2
Coating
NiCr-CrAl
Co-Al
Al-Si
Ti-Al

Cr
7
5
-

Co
9
14
9
-

Ti
1
1
5

Al
23
33
22
30

(mass fraction, %)
Si
Ni
Bal.
Bal.
3.5
Bal.
Bal.

25wt.% NaCl+75wt. % Na2SO4 17~20 mg/cm2


900 10 h 30 min
100 h
0.01 mg SEM
X XRD

2
2.1
900 1 3
1 900
NiCr-CrAlTi-Al 5 NiCr-CrAl
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Ti-Al Co-Al Al-Si NiCr-CrAl


Al-Si Ti-Al 70
70 Ti-Al
70 Al-Si
0.00

Mass gain per area, g/cm

-0.02

-0.04

-0.06

NiCr-CrAl coating
Co-Al coating
Al-Si coating
Al-Ti coating

-0.08

-0.10

-0.12
0

10

20

30

40

50

60

70

80

90

100

110

Time, h

1 900

2.2
900 100 h XRD 2

Internsity / a.u.

(a)

CoO -Al2O3 Cr2O3 TiO2 NiCr2O4

NiTiO3

(b)

(c)

20

25

30

35

(d)

40

45

50

55

60

65

70

75

80

85

2 / deg

2 900 100 XRD


(a) NiCr-CrAl (b) Co-Al (c) Al-Si (d) Ti-Al

2 900/100h NiO-Al2O3 NiCr2O4


NiTiO3Cr2O3 TiO2 NiO-Al2O3 NiCr2O4

NiTiO3
Cr2O3 TiO2
NiCr-CrAl 100 NiO
NiCr2O4
NiTiO3 -Al2O3 TiO2Cr2O3 NiCr-CrAl Co-Al
NiTiO3-Al2O3 TiO2 Al-Si
Ti-Al Co-Al NiCr-CrAl
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Cr2O3-Al2O3 NiCr2O4

2.3 100 h
900 100 h SEM 36
a

3 NiCr-CrAl 100
a;b

4 Co-Al 100
a b

5 Al-Si 100
a b

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6 Ti-Al 100
a b

36 NiCr-CrAlCo-AlAl-SiTi-Al 900 100h


/

3 NiCr-CrAl 100h
3b
4 Co-Al 100h
2a 4b
5 Al-Si 100h

5b
6 Ti-Al 100h 3a 4a
6b

2.4 100 h
a

7 100
aNiCr-CrAl bCo-Al cAl-Si dTi-Al
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900 100 h 7
7 NiCr-CrAlCo-AlAl-SiTi-Al 900 100h
Ti-Al Al-Si
7c
7a NiCr-CrAl
7b Co-Al 7d Ti-Al
2 Cr2O3-Al2O3 NiCr2O4

3
1 NiCr-CrAlCo-AlAl-Si Al-Ti

2 900 100h NiCr-CrAlCo-AlAl-Si

Al-Ti Al-Ti

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