Synergistic effects of laser modification and Al film deposition on the oxidation resistance of NiCoCrAlY coatings

IF 6.1 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology Pub Date : 2025-09-06 DOI:10.1016/j.surfcoat.2025.132636

Tao Zhou , Yunxia Ye , Dijuan Han , Shuai Jiang , Zhangqi Chen , Zhiyi Jin , Xudong Ren

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Abstract

Laser modification can alter the surface roughness and microstructure to improve the oxidation resistance of NiCoCrAlY coatings. However, its effectiveness is often limited by Al depletion during processing. In this study, NiCoCrAlY coatings prepared by atmospheric plasma spraying (APS) were treated by laser remelting and Al film deposition (1 μm). The oxidation behavior of the Modified and Modified-Al coatings was comparatively investigated at 950 °C. Results showed that, although laser treatment introduced high-density dislocations and grain refinement to enhance atomic diffusion, Al depletion in the Modified coating promoted the early formation of mixed oxides (Al₂O₃, Cr₂O₃ and NiO). With extended exposure, competitive oxidation between Al and Cr led to a double-layer thermally grown oxide (TGO), with an Al₂O₃-rich upper layer and Cr₂O₃ lower layer, which cracked due to the poor thermal stability of Cr₂O₃. In contrast, the Modified-Al coating formed a dense, continuous Al₂O₃ scale throughout the entire oxidation process, with a thickness about half that of the Modified coating after 200 h of oxidation. These results demonstrate that Al film deposition significantly enhanced the oxidation resistance of Modified coatings.

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激光改性与Al膜沉积对NiCoCrAlY涂层抗氧化性能的协同效应

激光改性可以改变NiCoCrAlY涂层的表面粗糙度和微观结构，从而提高涂层的抗氧化性能。然而，其有效性往往受到加工过程中铝损耗的限制。本研究对大气等离子喷涂（APS）制备的NiCoCrAlY涂层进行激光重熔和1 μm Al膜沉积处理。在950℃下，对比研究了改性铝涂层和改性铝涂层的氧化行为。结果表明，尽管激光处理引入了高密度位错和晶粒细化来增强原子扩散，但改性涂层中的Al消耗促进了混合氧化物（Al₂O₃，Cr₂O₃和NiO）的早期形成。随着暴露时间的延长，Al和Cr之间的竞争性氧化导致了双层热生长氧化物（TGO），上层富含Al₂O₃，下层富含Cr₂O₃，由于Cr₂O₃热稳定性差而破裂。相比之下，改性铝涂层在整个氧化过程中形成致密的、连续的Al₂O₃水垢，氧化200 h后，其厚度约为改性铝涂层的一半。结果表明，Al膜的沉积显著提高了改性涂层的抗氧化性。

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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.