Development of hybrid electrodeposition/slurry diffusion aluminide coatings on Ni-based superalloy with enhanced hot corrosion resistance

Zakeri, Alireza; Balashadehi, Mohammad Reza Masoumi; Rouhaghdam, A. Sabour

doi:10.52547/jcc.3.1.1

Cited by 11 publications

(12 citation statements)

References 40 publications

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“…Diffusion aluminide coatings are generally formed by the interdiffusion of alloying elements from the superalloys and an aluminium source (usually an Al donor) which protects the substrate superalloy from high temperature oxidation. Diffusion aluminide bond coatings are typically formed through incorporation of Al onto the components' surface by employing a combination of processes (mentioned in earlier sections) involving diffusion of Al [36], with pack cementation being predominantly studied [2,21,37]. However, oxidation resistance of the coating has been shown to be affected by oxide scale spallation due to an accelerated depletion of Al from the coating during thermal cycling.…”

Section: Diffusion Aluminidesmentioning

confidence: 99%

“…In addition to the above-mentioned metals and their combinations to produce intermediate electrodeposited layers, attempts were also made to create electrodeposited Ni and Ni-Co-modified coatings to function as diffusion aluminide coatings on post-treatment via the cementation, CVD techniques and so on. For instance, Zakeri [36] reported the preparation of Ni-Co-modified aluminide coatings on the Hastealloy-X substrate by a combined process of electrodeposition and slurry aluminizing. In this regard, pure layers of Ni and Ni-50 wt %Co were initially applied via an electrodeposition process and successive aluminising was carried out by a slurry technique.…”

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confidence: 99%

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Progress in Novel Electrodeposited Bond Coats for Thermal Barrier Coating Systems

Maniam

Paul

2021

Materials

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The increased demand for high performance gas turbine engines has resulted in a continuous search for new base materials and coatings. With the significant developments in nickel-based superalloys, the quest for developments related to thermal barrier coating (TBC) systems is increasing rapidly and is considered a key area of research. Of key importance are the processing routes that can provide the required coating properties when applied on engine components with complex shapes, such as turbine vanes, blades, etc. Despite significant research and development in the coating systems, the scope of electrodeposition as a potential alternative to the conventional methods of producing bond coats has only been realised to a limited extent. Additionally, their effectiveness in prolonging the alloys’ lifetime is not well understood. This review summarises the work on electrodeposition as a coating development method for application in high temperature alloys for gas turbine engines and discusses the progress in the coatings that combine electrodeposition and other processes to achieve desired bond coats. The overall aim of this review is to emphasise the role of electrodeposition as a potential cost-effective alternative to produce bond coats. Besides, the developments in the electrodeposition of aluminium from ionic liquids for potential applications in gas turbines and the nuclear sector, as well as cost considerations and future challenges, are reviewed with the crucial raw materials’ current and future savings scenarios in mind.

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Section: Diffusion Aluminidesmentioning

confidence: 99%

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confidence: 99%

Progress in Novel Electrodeposited Bond Coats for Thermal Barrier Coating Systems

Maniam

Paul

2021

Materials

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“…In this respect, utilizing Coatings rich in Al may be a useful approach to prevent the bad impacts of Al in the bulk of Ni-base superalloys while improving corrosion and oxidation resistance. Nickel-base superalloys are popular as base materials for hot components in industrial gas turbines such as blades or vanes due to their superior mechanical performance and high-temperature oxidation resistance [8]. On the other hand, the combustion gases' existence generates a harsh environment, as well as hot oxidation, which is inevitable when alloys are utilized at high temperatures for long durations of time [9].…”

Section: Introductionmentioning

confidence: 99%

Investigation of evaluated temperature oxidation for IN-738 LC superalloy turbine blade thermally coated by AL2O3 using slurry coating process

Mousa

Alshadeedi

Attia

et al. 2022

EEJET

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The study aims to investigate the effect of Al2O3 and Al additions to Nickel-base superalloys as a coating layer on oxidation resistance, and structural behavior of nickel superalloys such as IN 738 LC. Nickel-base superalloys are popular as base materials for hot components in industrial gas turbines such as blades due to their superior mechanical performance and high-temperature oxidation resistance, but the combustion gases' existence generates hot oxidation at high temperatures for long durations of time, resulting in corrosion of turbine blades which lead to massive economic losses. Turbine blades used in Iraqi electrical gas power stations require costly maintenance using traditional processes regularly. These blades are made of nickel superalloys such as IN 738 LC(Inconel 738). Few scientists investigated the impact of Al2O3 or Al additions to Nickel-base superalloys as coating layer by using the slurry coating method on oxidation resistance to enhance the Nickel-base superalloy's oxidation resistance. In this study, IN 738 LC is coated with two different coating percentages, the first being (10 Al+90 Al2O3) and the second being (40 Al+60 Al2O3). Scanning Electron Microscope (SEM) and X-Ray Diffraction (XRD) were performed on all samples before and after oxidation. According to the results, SEM images of the surface revealed that the layer of the surface has a relatively moderated porosity value and that some of the coating layers contain micro-cracks. The best surface roughness of specimens coated with 60 % alumina+40 % aluminum was 5.752 nm. Whereas, the surface roughness of specimens coated with 90 % alumina+10 % aluminum was 6.367 nm.Results reveal that alloys with both Al2O3 and Al additions have reported a positive synergistic effect of the Al2O3and Al additions on oxidation resistance. Moreover,the NiCrAl2O3 thermal coating has good oxidation resistance and the effective temperature of anti-oxidation is raised to 1100 °C in turn reducing the maintenance period of turbine blades

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“…There are several techniques to create coatings with fine microstructure such as spray deposition, electroplating, electron beam irradiation, slurry coating, pack cementation, and chemical vapor deposition. Each method has special advantages to control the thickness of the coating and the composition of the material [25][26][27][28][29]. To create a reliable UHTC coating and to optimize the penetration and adhesion of the carbon-carbon composite, understanding of the physical and chemical properties of the coating materials is [24,30].…”

Section: Introductionmentioning

confidence: 99%

Challenges toward applying UHTC-based composite coating on graphite substrate by spark plasma sintering

2021

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In this study, the UHTC-based composite layers where applied on the graphite substrates using SPS method to protect them against ablation. The protective layers had some defects and problems such as crack, fracture, separation, melting, and weak adhesion to the substrate. Several factors such as the thickness of composite layer, the number of protective layers, the SPS conditions (temperature, applied pressure, soaking time and mold), the chemical composition of the layers, the type of the substrate and the mismatch between the thermal expansion coefficients of the substrate and the applied layer(s) affected the quality and connection of the protective layer to the graphite substrate. The amount of additive materials influenced the melting phenomenon in the composite layer; for example, further MoSi2 in the layer led to more melting. The mismatch between the thermal expansion coefficients of the graphite substrate and the composite layer caused stresses during the cooling step, which resulted in cracks in the applied layer. Hence, proximity in the thermal expansion coefficients seems to be necessary for the formation of an acceptable adhesion between the layer and the substrate.

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Development of hybrid electrodeposition/slurry diffusion aluminide coatings on Ni-based superalloy with enhanced hot corrosion resistance

Cited by 11 publications

References 40 publications

Progress in Novel Electrodeposited Bond Coats for Thermal Barrier Coating Systems

Progress in Novel Electrodeposited Bond Coats for Thermal Barrier Coating Systems

Investigation of evaluated temperature oxidation for IN-738 LC superalloy turbine blade thermally coated by AL2O3 using slurry coating process

Challenges toward applying UHTC-based composite coating on graphite substrate by spark plasma sintering

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