Papers by Keyword: Diffusion Barrier Coating

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Authors: Toshio Narita, Takeshi Izumi, Takumi Nishimoto, Yoshimitsu Shibata, Kemas Zaini Thosin, Shigenari Hayashi
Abstract: To suppress interdiffusion between the coating and alloy substrate in addition to ensuring slow oxide growth at very high temperatures advanced coatings were developed, and they were classified into four groups, (1) the diffusion barrier coating with a duplex layer structure, an inner σ−(Re-Cr-Ni) phase as a diffusion barrier and outer Ni aluminides as an aluminum reservoir formed on a Ni based superalloy, Hastelloy X, and Nb-based alloy. (2) the up-hill diffusion coating with a duplex layer structure, an inner TiAl2 + L12 and an outer β-NiAl formed on TiAl intermetallic and Ti-based heat resistant alloys by the Ni-plating followed by high Al-activity pack cementation. (3) the chemical barrier coating with a duplex layer structure, an inner* γ + β + Laves three phases mixture as a chemical diffusion barrier and an outer Al-rich γ-TiAl as an Al reservoir formed by the two step Cr / Al pack process. (4) the self-formed coating with the duplex structure, an inner α-Cr layer as a diffusion barrier and an outer β-NiAl as an Al-reservoir on Ni-(2050)at% Cr alloy changed from the δ-Ni2Al3 coating during oxidation at high temperature. The oxidation properties of the coated alloys were investigated at temperatures between 1173 and 1573K in air for up to 1,000 hrs (10,000 hrs for the up-hill diffusion coating). In the diffusion barrier coating the Re-Cr-Ni alloy layer was stable, existing between the Ni-based superalloy (or Hastelloy X) and Ni aluminides containing 1250at%Al when oxidized at 1423K for up to 1800ks. It was found that the Re-Cr-Ni alloy layer acts as a diffusion barrier for both the inward diffusion of Al and outward diffusion of alloying elements in the alloy substrate. In the chemical barrier coating both the TiAl2 outermost and Al-rich γ-TiAl outer layers maintained high Al contents, forming a protective Al2O3 scale, and it seems that the inner, γ, β, Laves three phase mixture layer suppresses mutual diffusion between the alloy substrate and the outer/outermost layers.
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Authors: Shigenari Hayashi, Mikihiro Sakata, Shigeharu Ukai, Toshio Narita
Abstract: High temperature oxidation / creep deformation behavior of a diffusion barrier coated Hastelloy-X alloy, with large grain size ~500μm, was investigated at 970°C in air with external tensile stress of 22.5, 27.5, 32, and 40MPa. The diffusion barrier coating formed on Hastelloy-X consisted of a duplex structure with an inner diffusion barrier layer of Re-Cr-Ni alloy, and an outer oxidation resistant layer of β-NiAl. Un coated bare Hastelloy-X alloy with same grain size was also examined under the same conditions for comparison. The composition of the as-coated diffusion barrier coating was (15~21)Ni, (33~37)Cr, (30~33)Re, (11~15)Mo, and (9~14)Fe. This composition corresponds to σ-phase in the Ni-Cr-Re ternary system, which is known as a topologically close packed, TCP phase. The composition of this diffusion barrier layer did not change during the experiment. The oxide scales formed after creep testing on the coated and un-coated alloy surfaces were needle-like θ-Al2O3, and Cr2O3 with small amount of FeCr2O4, respectively. Grain boundary oxidation was also found in the subsurface region of the un-coated alloy. The Al2O3 scale exhibited severe spallation, and many cracks were formed perpendicular to the stress direction. However, no spallation or cracks were observed in the Cr2O3. The creep rupture times for the diffusion barrier coated alloy were about 1.5 times longer than those for bare alloy at all creep stress conditions. The fracture surface after rupture indicates that fracture occurred along alloy grain boundaries in both the coated and un-coated alloy substrate. Many cavities and cracks were observed within the diffusion barrier coated alloy substrate. These cavities and cracks tended to propagate from the substrate toward the diffusion barrier layer, and then stopped at the Re-Cr-Ni / β-NiAl interface. Cracks formed in the un-coated alloy initiated at the tip of grain boundary oxides, and propagated into alloy substrate. However no major cavities were observed inside the alloy substrate. The stress index, n, for both specimens was about 6, and this indicates that the deformation mechanism of both samples was dislocation creep. These results suggest that the Re-Cr-Ni diffusion barrier layer acts as a barrier against the movement of dislocations at the interface with the alloy surface.
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Authors: Toshio Narita, Shigenari Hayashi, Feng Qun Lang, Kemas Zaini Thosin
Abstract: A novel diffusion barrier bond coat with a duplex layer structure, a sigma phase Re-Cr-Ni barrier and Ni aluminides as an aluminum reservoir was formed on a Ni based superalloy (TMS 82+) and Hastelloy X. The oxidation behavior of both alloys with and without the sigma- Re-Cr-Ni -phase as a diffusion barrier was investigated at temperatures of 1373K (Hastelloy X) and 1423K (TMS-82+) for up to 360ks. It was found that the Re-Cr-Ni acts as a diffusion barrier for both inward diffusion of Al and outward diffusion of alloying elements in the alloy substrate.
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