Search

Owing to the diffusion of Si elements towards the metal substrate and the "pesting" behavior caused by volatilization of MoO 3 , magnetron-sputtered MoSi 2 coating is highly susceptible to failure and unable to protect the metal substrate from oxidation. In this work, therefore, an MoSi 2 (N) interlayer was sputtered on Mo substrates as the diffusion barrier, followed by deposition of Si-doped MoSi 2 (i.e., MoSi 2 (Si)) layer to suppress the "pesting" behavior. The as-deposited coatings were annealed subsequently at 1000 °C in an Ar atmosphere to obtain a stable structure. To evaluate the oxidation resistance, the annealed coating was heated in a muffle furnace in air at 700 °C, 1000 °C and 1200 °C for different durations. The coating structure, surface morphology, cross section and chemical composition were examined by X-ray diffraction, field emission scanning electron microscopy, and energy dispersive spectroscopy. The results showed the MoSi 2 (N) interlayer was amorphous and kept the most stable thermal stability at Ar/N 2 flow rate of 20/20 sccm. It effectively blocked the downward diffusion of Si. Free state Si elements only diffused towards the coating surface. "Pesting" pores in the MoSi 2 (Si) layer were repaired by the growth of SiO 2 layer via the preferential oxidation of Si. The mechanism for the enhanced oxidation resistance was explained through a model. • Amorphous MoSi 2 (N) interlayer is an effective diffusion barrier. • MoSi 2 (N) interlayer blocks diffusion of Si elements in MoSi 2 (Si) coating to enhance oxidation resistance of Mo substrate. • "Pesting" pores are repaired by growth of SiO 2 layer via oxidation of Si. [ABSTRACT FROM AUTHOR]

A novel Cr barrier layer was designed for suppressing the interdiffusion of an AlSi alloy coating on stainless steel. Without a Cr barrier layer, the same coating experienced a severe element interdiffusion upon exposure to high-temperature air. The rapid upward movement of the Fe atoms induced the formation of the (FeAl + Fe 2 Al 5) alloy compounds and eventually led to severe volume shrinkage and the ultimate fracture of coating. The significant downward diffusion of the (Al + Si) atoms not only triggered numerous pores but also induced the accumulation of the FeAl alloy compound in the substrate resulting in extreme interfacial cracking. In contrast, a diffusion barrier layer comprising (Cr 2 O 3 + SiO 2) and Al 2 O 3 was formed in the coating with a Cr layer during high-temperature exposure, effectively preventing the rapid elemental interdiffusion. Moreover, it inhibited the formation of the (FeAl + Fe 2 Al 5) alloy compounds in the coating as well as prevented the accumulation of the FeAl in the substrate. The obvious upward diffusion of Cr atoms further healed these pores induced by the downward diffusion of (Al + Si) atoms. The strong barrier capability of this composite oxide layer and the healing effect of Cr diffusion eventually led to an improved oxidation resistance of the Cr-coated layer. • Effect of Cr layer on the oxidation resistance of AlSi alloy coating was investigated. • The Cr diffusion triggered the growth of the (Al 2 O 3 + SiO 2) and Al 2 O 3 barrier layer. • This oxide barrier layer effectively suppressed severe inerdiffusion of Fe and Al. • The sufficient upward diffusion of Cr induced a significant self-healing effect. • The AlSi alloy coating with a Cr layer showed an improved oxidation resistance. [ABSTRACT FROM AUTHOR]

A novel Cr barrier layer was designed for suppressing the interdiffusion of an AlSi alloy coating on stainless steel. Without a Cr barrier layer, the same coating experienced a severe element interdiffusion upon exposure to high-temperature air. The rapid upward movement of the Fe atoms induced the formation of the (FeAl + Fe 2 Al 5) alloy compounds and eventually led to severe volume shrinkage and the ultimate fracture of coating. The significant downward diffusion of the (Al + Si) atoms not only triggered numerous pores but also induced the accumulation of the FeAl alloy compound in the substrate resulting in extreme interfacial cracking. In contrast, a diffusion barrier layer comprising (Cr 2 O 3 + SiO 2) and Al 2 O 3 was formed in the coating with a Cr layer during high-temperature exposure, effectively preventing the rapid elemental interdiffusion. Moreover, it inhibited the formation of the (FeAl + Fe 2 Al 5) alloy compounds in the coating as well as prevented the accumulation of the FeAl in the substrate. The obvious upward diffusion of Cr atoms further healed these pores induced by the downward diffusion of (Al + Si) atoms. The strong barrier capability of this composite oxide layer and the healing effect of Cr diffusion eventually led to an improved oxidation resistance of the Cr-coated layer. • Effect of Cr layer on the oxidation resistance of AlSi alloy coating was investigated. • The Cr diffusion triggered the growth of the (Al 2 O 3 + SiO 2) and Al 2 O 3 barrier layer. • This oxide barrier layer effectively suppressed severe inerdiffusion of Fe and Al. • The sufficient upward diffusion of Cr induced a significant self-healing effect. • The AlSi alloy coating with a Cr layer showed an improved oxidation resistance. [ABSTRACT FROM AUTHOR]

To solve the issue of elemental interdiffusion between protective coating and superalloy substrate during high-temperature service, an AlCoCrNiMo high-entropy alloy (HEA) diffusion barrier was deposited by direct current magnetron sputtering between NiAlHf protective coating and Ni-based single crystal superalloy (René N5). The interdiffusion behavior and high-temperature oxidation resistance of the coating system were investigated via isothermal oxidation at 1373 K. After long-term oxidation at 1373 K, no interdiffusion zone (IDZ), secondary reaction zone (SRZ) and rod/needle-like topologically close-packed (TCP) precipitates were observed in the coating system with HEA diffusion barrier. Besides, the NiAlHf coating exhibited an improved oxidation resistance with the addition of HEA diffusion barrier. The results indicate that the HEA diffusion barrier can suppress the interdiffusion of alloying elements between substrate and coating effectively, which is attributed to the sluggish diffusion effect of HEA and the in-suit formed alumina layers at the substrate/HEA and HEA/NiAlHf interfaces during high-temperature oxidation. Moreover, it was found that the Co element in HEA layer also plays an important role in suppressing the formation of SRZ and TCP precipitates in the superalloy. [Display omitted] • An AlCoCrNiMo high-entropy alloy is adopted as the diffusion barrier. • Diffusion barrier effectively retards the elemental interdiffusion at 1373 K. • NiAlHf coating with diffusion barrier shows an improved oxidation resistance. • Co element plays an important role in suppressing the formation of precipitates. [ABSTRACT FROM AUTHOR]

CoCrAlYTaSi coatings with different Al 2 O 3 mass fractions were fabricated on Ti–6Al–4V alloy using a laser cladding (LC). The effects of Al 2 O 3 mass fractions on the microstructure, oxidation resistance and friction–wear performance of obtained coatings were investigated, and the wear mechanisms were also discussed. The results show that the hardness of CoCrAlYTaSi coating increases with the increase of Al 2 O 3 mass fractions, the dendritic structure with the Al 2 O 3 mass fraction of 15% is compactly refined. The diffusion barrier layer of Al 2 O 3 contains Y oxide precipitate, which reduces the oxidation rate and the movement of Ta. The total mass gain per unit area of CoCrAlYTaSi coating with the Al 2 O 3 mass fractions of 15, 30 and 45% is 33.96, 29.82, and 26.27 mg •cm−2, respectively, the oxidation resistance with the Al 2 O 3 mass fraction of 15% is the best among the three kinds of coatings. The average coefficients of friction (COFs) of CoCrAlYTaSi coatings with the Al 2 O 3 mass fractions of 0, 15, 30 and 45% are 1.12, 0.17, 0.23, and 0.35, respectively, and the corresponding wear rates of are 1.59 × 10−4, 1.02 × 10−4, 0.54 × 10−4, and 0.3 × 10−4 mm3 N−1•m−1, respectively, the wear mechanism is abrasive wear and micro–cutting. • The dendritic structure of CoCrAlYTaSi coating decreased with the increase of Al 2 O 3 mass fractions. • The hardness of CoCrAlYTaSi coatings increased with the increase of Al 2 O 3 mass fractions. • The total mass gains per unit area of CoCrAlYTaSi coatings decreased with the increase of Al 2 O 3 mass fractions. • The Al 2 O 3 mass fractions affect the average COFs and wear rates of CoCrAlYTaSi coatings. [ABSTRACT FROM AUTHOR]