Phase Evolution and Oxidation Resistance of YSZ/(Ni, Al) Composite Coatings in CH₄ Atmosphere

Abstract

YSZ/(Ni, Al) composite coatings with different Ni:Al mole ratios were deposited on superalloy Inconel 600 by electrophoretic deposition (EPD) technique, followed by sintering in CH₄ atmosphere at 1 100 °C for 2 h and isothermally oxidation at 1000 °C for 50 h. After sintering at 1100 °C for 2 h in CH₄ atmosphere, besides ZrC and t-ZrO₂ phases, the phase constitutes of Ni:Al mole ratios with 1:3, 1:2, and 1:1 were (Zr, Al)C, AlNi₃ and Ni phases, respectively. A remarkable difference in the oxidation behaviors of YSZ/(Ni, Al) composite coatings with different Ni:Al mole ratios was observed. For YSZ(Ni:Al=1:3) coated sample, oxidation at 1000 °C causes decomposition of the (Zr,Al)C solid solution to metallic Al, and then most of the Al is oxidized to Al₂O₃. For the YSZ(Ni:Al=1:2) coated sample, oxidation at 1000 °C mainly causes decomposition of the AlNi₃ phase. For YSZ(Ni:Al=1:1) coated sample, after oxidation at 1000 °C, most of the Ni is oxidized to NiO phase, and tolerated 50 h of oxidation and finally cracked and spalled from the specimen. YSZ(Ni:Al=1:3) and YSZ(Ni:Al=1:2) coated samples show superior oxidation resistance than that of YSZ coating. The different oxidation resistance mechanisms of YSZ/(Ni, Al) composite coatings sintered in CH₄ atmosphere were discussed.

Keywords

EPD / composite coatings / oxidation resistance / phase transformation

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