Elucidating the formation mechanism of Fe/Mn oxide buildup at 1000 °C upon CoNiCrAlY coatings reinforced with nano-ZrB2

IF 5.3 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology Pub Date : 2025-03-06 DOI:10.1016/j.surfcoat.2025.132016

Kang Yang, Zitao Jiang, Guozheng Xu, Shihong Zhang

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引用次数: 0

Abstract

In this study, the microstructure evolution and formation mechanism of Fe/Mn oxide buildup on HVOF sprayed CoNiCrAlY-ZrB₂ and CoNiCrAlY coatings at 1000 °C were investigated. CoNiCrAlY-ZrB₂ composite powder (D50 = 38.6 μm) with uniformly distributed nano-ZrB₂ in CoNiCrAlY matrix was prepared by the 35-h step-fashion mechanical alloying. Results show that high-quality CoNiCrAlY-ZrB₂ coating and CoNiCrAlY coating can be prepared by HVOF. Compared to the CoNiCrAlY-ZrB₂ coating, the CoNiCrAlY coating has been extensively covered by the (Mn, Fe)Al₂O₄ deposits accompanied by peeling before 20 h, which were formed by the reaction between Fe/Mn elements and Al₂O₃ layer, indicating poor resistance to Fe/Mn oxide buildup. A mixed oxide layer of Cr₂O₃ and ZrO₂ on the CoNiCrAlY-ZrB₂ coating can remain unpeeled for up to 65 h, and effectively prevent the formation of Fe/Mn oxide deposits. The composite coating is completely covered by the deposits only after 100 h. The formation mechanism of Fe/Mn oxide buildup on CoNiCrAlY-ZrB₂ coating is significantly affected by the addition and dispersion of nano-ZrB₂ ceramics, which can promote the formation of the protective mixed oxide layer. The CoNiCrAlY composite coating exhibits excellent resistance to the Fe/Mn oxide buildup, which is a high potential for protecting high-temperature hearth rolls.

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来源期刊

Surface & Coatings Technology 工程技术-材料科学：膜

CiteScore

10.00

自引率

11.10%

发文量

921

审稿时长

19 days

期刊介绍： Surface and Coatings Technology is an international archival journal publishing scientific papers on significant developments in surface and interface engineering to modify and improve the surface properties of materials for protection in demanding contact conditions or aggressive environments, or for enhanced functional performance. Contributions range from original scientific articles concerned with fundamental and applied aspects of research or direct applications of metallic, inorganic, organic and composite coatings, to invited reviews of current technology in specific areas. Papers submitted to this journal are expected to be in line with the following aspects in processes, and properties/performance: A. Processes: Physical and chemical vapour deposition techniques, thermal and plasma spraying, surface modification by directed energy techniques such as ion, electron and laser beams, thermo-chemical treatment, wet chemical and electrochemical processes such as plating, sol-gel coating, anodization, plasma electrolytic oxidation, etc., but excluding painting. B. Properties/performance: friction performance, wear resistance (e.g., abrasion, erosion, fretting, etc), corrosion and oxidation resistance, thermal protection, diffusion resistance, hydrophilicity/hydrophobicity, and properties relevant to smart materials behaviour and enhanced multifunctional performance for environmental, energy and medical applications, but excluding device aspects.