Characterization of MCrAlY/nano-Al₂O₃ nanocomposite powder produced by high-energy mechanical milling as feedstock for high-velocity oxygen fuel spraying deposition

Abstract

Al₂O₃ nanoparticles and MCrAlY/nano-Al₂O₃ nanocomposite powder (M = Ni, Co, or NiCo) were produced using high-energy ball milling. The MCrAlY/nano-Al₂O₃ coating was deposited by selecting an optimum nanocomposite powder as feedstock for high-velocity oxygen fuel thermal spraying. The morphological and microstructural examinations of the Al₂O₃ nanoparticles and the commercial MCrAlY and MCrAlY/nano-Al₂O₃ nanocomposite powders were investigated using X-ray diffraction analysis, field-emission scanning electron microscopy coupled with electron dispersed spectroscopy, and transmission electron microscopy. The structural investigations and Williamson-Hall results demonstrated that the ball-milled Al₂O₃ powder after 48 h has the smallest crystallite size and the highest amount of lattice strain among the as-received and ball-milled Al₂O₃ owing to its optimal nanocrystalline structure. In the case of developing MCrAlY/nano-Al₂O₃ nanocomposite powder, the particle size of the nanocomposite powders decreased with increasing mechanical-milling duration of the powder mixture.

Keywords

MCrAlY / Nanocomposite powder / High-energy mechanical milling / Williamson-Hall analysis / HVOF coating

References

[1] Hardwicke CU, Lau YC. Advances in thermal spray coatings for gas turbines and energy generation: A review. J. Therm. Spray Technol., 2013, 22(5): 564.

[2] Pulci G, Tirillò J, Marra F, Sarasini F, Bellucci A, Valente T, Bartuli C. High temperature oxidation and microstructural evolution of modified MCrAlY coatings. Metall. Mater. Trans. A, 2014, 45(3): 1401.

[3] Achar DRG, Munoz-Arroyo R, Singheiser L, Quadakkers WJ. Modelling of phase equilibria in MCrAlY coating systems. Surf. Coat. Technol., 2004, 187(2): 272.

[4] Taie I, Al-Shahrani A, Qari N, Fihri A, Al-Obaid W, Alabedi G. High temperature corrosion resistant coatings for gas flare systems. Ceram. Int., 2018, 44(5): 5124.

[5] Abedi HR, Salehi M, Shafyei A. Mechanical and thermal properties of double-layer and triple-layer thermal barrier coatings with different ceramic top coats onto polyimide matrix composite. Ceram. Int., 2017, 43(15): 12770.

[6] Jam A, Derakhshandeh SMR, Rajaei H, Pakseresht AH. Evaluation of microstructure and electrochemical behavior of dual-layer NiCrAlY/mullite plasma sprayed coating on high silicon cast iron alloy. Ceram. Int., 2017, 43(16): 14146.

[7] Ghadami F, Sabour Rouh Aghdam A. Improvement of high velocity oxy-fuel spray coatings by thermal post-treatments: A critical review. Thin Solid Films, 2019, 678, 42.

[8] Kumar D, Pandey KN, Das DK. Microstructure studies of air-plasma-spray-deposited conicraly coatings before and after thermal cyclic loading for high-temperature application. Int. J. Miner. Metall. Mater., 2016, 23(8): 934.

[9] Hou GL, An YL, Zhao XQ, Zhou HD, Chen JM. Effect of alumina dispersion on oxidation behavior as well as friction and wear behavior of hvof-sprayed CoCrAlYTaCSi coating at elevated temperature up to 1000°C. Acta Mater., 2015, 95, 164.

[10] Zhao L D, Lugscheider E. High velocity oxy-fuel spraying of a NiCoCrAlY and an intermetallic NiAl-TaCr alloy. Surf. Coat. Technol., 2002, 149(2): 230.

[11] Fan L, Chen HY, Dong YH, Dong LH, Yin YS. Wear and corrosion resistance of laser-cladded Fe-based composite coatings on AISI 4130 steel. Int. J. Miner. Metall. Mater., 2018, 25(6): 716.

[12] Tao C, Wang L, Song X. High-temperature frictional wear behavior of MCrAlY-based coatings deposited by atmosphere plasma spraying. Int. J. Miner. Metall. Mater., 2017, 24(2): 222.

[13] Jithesh K, Arivarasu M. Comparative studies on the hot corrosion behavior of air plasma spray and high velocity oxygen fuel coated Co-based L605 superalloys in a gas turbine environment. Int. J. Miner. Metall. Mater., 2020, 27(5): 649.

[14] Tobar MJ, Amado JM, Yáñez A, Pereira JC, Amigó V. Laser cladding of MCrAlY coatings on stainless steel. Phys. Procedia, 2014, 56, 276.

[15] Huang T, Bergholz J, Mauer G, Vassen R, Naumenko D, Quadakkers WJ. Effect of test atmosphere composition on high-temperature oxidation behaviour of CoNiCrAlY coatings produced from conventional and ODS powders. Mater. High Temp., 2018, 35(1–3): 97.

[16] Bergholz J, Pint BA, Unocic KA, Vaßen R. Fabrication of oxide dispersion strengthened bond coats with low Al₂O₃ content. J. Therm. Spray Technol., 2017, 26(5): 868.

[17] Ghadami F, Sohi MH, Ghadami S. Effect of bond coat and post-heat treatment on the adhesion of air plasma sprayed WC-Co coatings. Surf. Coat. Technol., 2015, 261, 289.

[18] Ghadami F, Ghadami S, Abdollah-Pour H. Structural and oxidation behavior of atmospheric heat treated plasma sprayed WC-Co coatings. Vacuum, 2013, 94, 64.

[19] F. Ghadami, A. Sabour Rouh Aghdam, S. Ghadami, and Q. Zeng, Effect of vacuum heat treatment on the oxidation kinetics of freestanding nanostructured NiCoCrAlY coatings deposited by high-velocity oxy-fuel spraying, J. Vac. Sci. Technol. A, 38(2020), No. 2, art. No. 022601.

[20] Ghadami F, Sabour Rouh Aghdam A, Ghadami S. Abrasive wear behavior of nano-ceria modified NiCoCrAlY coatings deposited by the high-velocity oxy-fuel process. Mater. Res. Express, 2020, 6(12): 1250d6.

[21] Heydarzadeh Sohi M, Ghadami F. Comparative tribological study of air plasma sprayed WC-12%Co coating versus conventional hard chromium electrodeposit. Tribol. Int., 2010, 43(5): 882.

[22] Ghadami S, Taheri-Nassaj E, Baharvandi HR, Ghadami F. Effect of SiC and MoSi₂ in situ phases on the oxidation behavior of HfB₂-based composites. Ceram. Int., 2020, 46(12): 20299.

[23] Sayyadi-Shahraki A, Rafiaei SM, Ghadami S, Nekouee KA. Densification and mechanical properties of spark plasma sintered Si₃N₄/ZrO₂ nano-composites. J. Alloys Compd., 2019, 776, 798.

[24] Ghadami S, Taheri-Nassaj E, Baharvandi HR. Novel HfB₂-SiC-MoSi₂ composites by reactive spark plasma sintering. J. Alloys Compd., 2019, 809, 151705.

[25] Ghadami S, Baharvandi HR, Ghadami F. Influence of the vol% SiC on properties of pressureless Al₂O₃/SiC nanocomposites. J. Compos. Mater., 2016, 50(10): 1367.

[26] Ghadami S, Taheri-Nassaj E, Baharvandi HR, Ghadami F. Effect of in situ VSi₂ and SiC phases on the sintering behavior and the mechanical properties of HfB₂-based composites. Sci. Rep., 2020, 10(1): 16540.

[27] Ghadami F, Heydarzadeh Sohi M, Ghadami S. Effect of TIG surface melting on structure and wear properties of air plasma-sprayed WC-Co coatings. Surf. Coat. Technol., 2015, 261, 108.

[28] Bobzin K, Schläfer T, Richardt K, Brühl M. Development of oxide dispersion strengthened MCrAlY coatings. J. Therm. Spray Technol., 2008, 17, 853.

[29] Tang F, Ajdelsztajn L, Schoenung JM. Influence of cryomilling on the morphology and composition of the oxide scales formed on hvof CoNiCrAlY coatings. Oxid. Met., 2004, 61(3): 219.

[30] Ghadami F, Zakeri A, Aghdam ASR, Tahmasebi R. Structural characteristics and high-temperature oxidation behavior of HVOF sprayed nano-CeO₂ reinforced NiCoCrAlY nanocomposite coatings. Surf. Coat. Technol., 2019, 373, 7.

[31] F. Ghadami and A.S. Rouh Aghdam, Preparation of NiCrAlY/nano-CeO₂ powder with the core-shell structure using high-velocity oxy-fuel spraying process, Mater. Chem. Phys., 243(2020), art. No. 122551.

[32] S. Ghadami S, E. Taheri-Nassaj, H.R. Baharvandi and F. Ghadami, Improvement of mechanical properties of HfB 2-based composites by incorporating in situ SiC reinforcement through pressureless sintering, Sci. Rep., 11(2021), art. No. 9835.

[33] Sameezadeh M, Farhangi H, Emamy M. Structural characterization of AA 2024-MoSi₂ nanocomposite powders produced by mechanical milling. Int. J. Miner. Metall. Mater., 2013, 20(3): 298.

[34] Li B, Jia J, Gao Y, Han M, Wang W. Microstructural and tribological characterization of NiAl matrix self-lubricating composite coatings by atmospheric plasma spraying. Tribol. Int., 2017, 109, 563.

[35] Khodsiani Z, Mansuri H, Mirian T. The effect of cryomilling on the morphology and particle size distribution of the NiCoCrAlYSi powders with and without nano-sized alumina. Powder Technol., 2013, 245, 7.

[36] Mahesh RA, Jayaganthan R, Prakash S. A study on the oxidation behavior of HVOF sprayed NiCrAlY-0.4wt.% CeO₂ coatings on superalloys at elevated temperature. Mater. Chem. Phys., 2010, 119(3): 449.

[37] Kamal S, Jayaganthan R, Prakash S. Mechanical and microstructural characteristics of detonation gun sprayed NiCrAlY+0.4wt% CeO₂ coatings on superalloys. Mater. Chem. Phys., 2010, 122(1): 262.

[38] Ghadami F, Sabour Rouh Aghdam A, Zakeri A, Saeedi B, Tahvili P. Synergistic effect of CeO₂ and Al₂O₃ nanoparticle dispersion on the oxidation behavior of MCrAlY coatings deposited by HVOF. Ceram. Int., 2020, 46(4): 4556.

[39] Ghadam F, Rouh Aghdam AS, Ghadami S. Preparation, characterization and oxidation behavior of CeO₂-gradient NiCrAlY coatings applied HVOF thermal spraying process. Ceram. Int., 2020, 46(12): 20500.

[40] Williamson GK, Hall WH. X-ray line broadening from filed aluminium and wolfram. Acta Metall., 1953, 1(1): 22.

[41] Anghel EM, Marcu M, Banu A, Atkinson I, Paraschiv A, Petrescu S. Microstructure and oxidation resistance of a NiCrAlY/Al₂O₃-sprayed coating on Ti-19Al-10Nb-V alloy. Ceram. Int., 2016, 42(10): 12148.

[42] Tahari M, Shamanian M, Salehi M. Microstructural and morphological evaluation of MCrAlY/YSZ composite produced by mechanical alloying method. J. Alloys Compd., 2012, 525, 44.

[43] Mercier D, Gauntt BD, Brochu M. Thermal stability and oxidation behavior of nanostructured NiCoCrAlY coatings. Surf. Coat. Technol., 2011, 205(17–18): 4162.

[44] Suryanarayana C. Mechanical alloying and milling, 2001, 46(1–2): 1.

[45] Saeidi S, Voisey KT, McCartney DG. The effect of heat treatment on the oxidation behavior of HVOF and VPS CoNiCrAlY coatings. J. Therm. Spray Technol., 2009, 18(2): 209.

[46] Sachan R, Park JW. Formation of nanodispersoids in Fe-Cr-Al/30%TiB₂ composite system during mechanical alloying. J. Alloys Compd., 2009, 485(1–2): 724.

[47] Ajdelsztajn L, Picas JA, Kim GE, Bastian FL, Schoenung J, Provenzano V. Oxidation behavior of HVOF sprayed nanocrystalline NiCrAlY powder. Mater. Sci. Eng. A, 2002, 338(1–2): 33.

[48] Suryanarayana C. Synthesis of nanocomposites by mechanical alloying. J. Alloys Compd., 2011, 509, S229.

[49] Sharma P, Dutta Majumdar J. Studies on nano-crystalline CoNiCrAlY consolidated by conventional and microwave sintering. Adv. Powder Technol., 2016, 27(1): 72.

[50] Daroonparvar M, Hussain MS, Yajid MAM. The role of formation of continues thermally grown oxide layer on the nanostructured NiCrAlY bond coat during thermal exposure in air. Appl. Surf. Sci., 2012, 261, 287.

[51] Rana N, Mahapatra MM, Jayaganthan R, Prakash S. Deposition of nanocrystalline coatings by modified LVOF thermal spray method. J. Alloys Compd., 2014, 615, 779.

[52] Zhao LD, Parco M, Lugscheider E. Wear behaviour of Al₂O₃ dispersion strengthened MCrAlY coating. Surf. Coat. Technol., 2004, 184(2–3): 298.

[53] Ghadami F, Sabour Rouh Aghdam A, Ghadami S. Mechanism of the oxide scale formation in thermally-sprayed NiCoCrAlY coatings modified by CeO₂ nanoparticles. Mater. Today Commun., 2020, 24, 101357.