DEPOSITION OF ALUMINIDE AND CHROMIUM-MODIFIED ALUMINIDE COATINGS ON TiAl ALLOYS USING THE HALIDE-ACTIVATED PACK CEMENTATION METHOD

The halide activated pack cementation method is utilized to deposit aluminide and chromium modified aluminide coatings on TiAl alloys. Emphasis is placed on the effect of alloying elements on the aluminizing kinetics as well as on the study of formation of chromium modified aluminide coating. The addition of a small amount of Nb and Cr in the TiAl improves significantly the aluminizing kinetics of TiAl alloys by increasing the reaction rate of active Al atoms with substrate through grain refinement as well as by increasing the solid state diffusion of Al through the formation of stable TiAl 3 layer. Cr and Al are simultaneously co deposited by diffusion into K 5 alloy, by a single step, pack cementation process. The morphologies of the coating formed on K 5 substrate, i.e., an external layer with L1 2 structure and an underlying interdiffusion zone, are presented. The mechanism for the formation of Cr modified aluminide coating is discussed.

A STUDY ON ALUMINIDE COATINGS ON TiAl ALLOYS BY PACKCEMENTATION METHOD

The halide-activated pack cementation method is utilized to deposit aluminide coat- ings on TiAl alloys. Emphasis is placed on the effect of alloying elements on the aluminizing behavior of TiAl alloy. The addition of a small amount of Nb or Cr in the TiAl improves significantly the aluminizing kinetics of TiAl alloys by increasing the solid-state division of Al through the formation of stable TiAl3 layer. The TiAl3 layer formed on the TiAl alloyed with Nb or Cr has better toughness than the TiAl3 formed on the non-alloyed TiAl. The reason for better toughness of the coating formed on TiAl is that partial TiAl3 with tetragonal structure was changed to high symmetry cubic L12 structure since Nb or Cr was dissolved into TiAl3. The TiAl3 layer formed on the TiAl alloyed with Nb or Cr has much better oxidation resistance than the TiAl3 layer formed on the non-alloyed TiAl. It is attributed to change in the crystal structure of TiAl3 from the brittle tetragonal DO22 to the ductile cubic L12 by addition of small amount of Nb or Cr.

Microstructure and high temperature oxidation resistance of Si-Y co-deposition coatings prepared on TiAl alloy by pack cementation process

In order to improve the high temperature oxidation resistance of TiAl alloy, Y modified silicide coatings were prepared by pack cementation process at 1030, 1080 and 1130 °C, respectively, for 5 h. The microstructures, phase constitutions and oxidation behavior of these coatings were studied. The results show that the coating prepared by co-depositing Si?Y at 1080 °C for 5 h has a multiple layer structure: a superficial zone consisting of Al-rich (Ti,Nb)5Si4 and (Ti,Nb)5Si3, an out layer consisting of (Ti,Nb)Si2, a middle layer consisting of (Ti,Nb)5Si4 and (Ti,Nb)5Si3, and aγ-TiAl inner layer. Co-deposition temperature imposes strong influences on the coating structure. The coating prepared by Si?Y co-depositing at 1080 °C for 5 h shows relatively good oxidation resistance at 1000 °C in air, and the oxidation rate constant of the coating is about two orders of magnitude lower than that of the bare TiAl alloy.

Low-temperature Formation of Aluminide Coatings on Ni-base Superalloys by Pack Cementation Process

This article investigates the low-temperature formation of aluminide coatings on a Ni-base superalloy by pack cementation process. The pack cemented coatings characteristic of high density and homogeneity possess a two-layer structure. The top layer mainly consists of Al3Ni2 and Al3Ni,while the bottom layer of Al3Ni2. Great efforts are made to elucidate the effects of different experimental parameters on the microstructure and the constituent distribution of the coatings. The results show that all the parameters exclusive of the pack activator （NH4Cl） content produce effect on the coating thickness,but do not on the microstructure and the constituent distribution. The pack activator （NH4Cl） content affects neither the coating thickness nor structure and constituent distribution. The parabolic relationship between the coating thickness and the deposition time suggests that the process is diffusion-controlled. Furthermore,the article demonstrates a linear relationship between the coating thickness and the re-ciprocal deposition temperature.

Pack Aluminide Coatings Formed at 650℃ for Enhancing Oxidation Resistance of Low Alloy Steels

This study aims to investigate the feasibility of forming iron aluminide coatings on a commercial 9Cr-lMo (wt.%) alloy steel by pack cementation at 650 °C in an attempt to improve its high temperature oxidation resistance. Pack powders containing Al, A12O3 and a series of halide salts were used to carry out the coating deposition experiments, which enabled identification of the most suitable activator for the pack aluminising process at the intended temperature. The effect of pack aluminium content on the growth kinetics and microstructure of the coatings was then studied by keeping deposition conditions and pack activator content constant while increasing the pack aluminium content from 1.4 wt.% to 6 wt.%. X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) techniques were used to analyse the phases and microstructures of the coatings formed and to determine depth profiles of coating elements in the coating layer. Oxidation resistance of the coating was studied at 650 °C in air by intermittent weight measurement at room temperature. It was observed that the coating could substantially enhance the oxidation resistance of the steel under these testing conditions, which was attributed to the capability of the iron aluminide phases to form alumina scale on the coating surface through preferential Al oxidation.

Effect of Substrate Characteristics on Interdiffusion Coefficients of Ni and Al Atoms in β-NiAl Phase of Aluminide Coatings

Interdiffusion coefficients at 950℃ and 1050℃ are calculated by Wagner analysis method as a function of composition of β-NiAI phase. The β-NiAI phase is formed by pack cementation on surface of superalloy. Results of the calculation show that interdiffusion coefficients in β-NiAI phase strongly depend on the compositions and vary over several orders of magnitude. Compared with the interdiffusion coefficients in the stoichiometric β-NiAI phase, the interdiffusion coefficients in β-NiAI phase formed on superalloy is obviously small, probably due to the composition, complicated microstructure and precipitates. However, it could be seen clearly that the shapes of the diffusivity curves are very similar to each other. The similarity of the diffusion curves and the difference between interdiffusion coefficients imply that the compositions, microstructures and precipitates of superalloy have a distinctly adverse effect on the interdiffusion of Ni and Al atoms during aluminization, but do not change the essential characteristics of β-NiAI phase.

Microstructure and Growth Kinetics of Silicide Coatings for TiAl Alloy

In order to improve the oxidation resistance of Ti Al alloy, silicide coatings were prepared by pack cementation method at 1273, 1323, and 1373 K for 1-3 hours. Scanning electron microscopy（SEM）, energy dispersive spectrometry（EDS） and X-ray diffraction（XRD） were employed to investigate the microstructures and phase constitutions of the coatings. The experimental results show that all silicon deposition coatings have multi-layer structure. The microstructure and composition of silicide coatings strongly depend on siliconizing temperatures. In order to investigate the rate controlling step of pack siliconizing on Ti Al alloy, coating growth kinetics was analyzed by measuring the mass gains per unit area of silicided samples as a function of time and temperature. The results showed that the rate controlling step was gas-phase diffusion step and the growth rate constant（k） ranged from 1.53 mg^2/（cm^4·h^2） to 2.3 mg^2/（cm^4·h^2）. Activation energy（Q） for the process was calculated as 109 k J/mol, determined by Arrhenius＇ equation： k = k0 exp[–Q/（RT）].

Improving hot corrosion resistance of aluminized TiAl alloy by anodization and pre-oxidation

To shield TiAl alloy from hot corrosion attack,a compact protective coating was fabricated by the combination of aluminizing,anodization and pre-oxidation.The hot corrosion behavior of the coated-TiAl specimen was investigated in the mixture salt consisting of 75 wt.%Na2SO4 and 25 wt.%NaCl at 700°C.Results indicated that the anodization and pre-oxidation were beneficial to the generation of Al2O3 layer,which could act as a diffusion barrier to prevent the molten salts and oxygen from diffusing into the alloy during exposure to a hot corrosion environment while the aluminizing coating could provide sufficient aluminum source to support the continuous formation of Al2O3 layer.Moreover,the internal stress of the coating was reduced due to the formation of a gradient coating consisting of TiAl3 and TiAl2.

Formation and Characterization of Titanium Modified Aluminide Coatings on IN738LC

Up to now, the aluminide coatings used to protect industrial components at high temperature and corrosive environments have been modified by Pt, Cr, Si and Ni. In this investigation, aluminide coatings were modified by titanium and the microstructural feature and formation mechanism were evaluated. The coatings were formed on a Ni-based superalloy(IN738LC) by a two stage process including titanizing at first and aluminizing thereafter. Pack cementation titanizing performed at temperatures 950° C and 1050° C in several mixtures of Ti, A12O3 and NH^Cl. At the second stage, aluminum diffused into surface of the specimens by an industrial aluminizing process known as Elcoatl01(4 hrs at 1050° C). The modified coatings were characterized by means of standard optical microscopy, scanning electron microscopy, energy dispersive spectroscopy and X-Ray diffraction methods. The results show that Ti in the coatings is mainly present in the form of TiNi and Al67Cr8Ti25. Titanium modified coatings grew with a mechanism similar to simple aluminizing; this includes inward diffusion of Al from the pack to the substrate and then outward diffusion of Ni from the substrate to the coating. The advantages and characteristics of this two-stage modified coating is discussed and the process parameters are proposed to obtain a coating of optimum microstructure.

Formation and Microstructural Characterization of Silicon-modified Aluminide Coating on Nickel-based Superalloy IN738LC

In this investigation, aluminide coatings used to protect industrial components at high temperature and corrosive environments were modified with silicon addition and the microstructural features and formation mechanism were evaluated. The coating on the nickel-based superalloy IN738LC was carried out by a two stage process including siliconizing at first and aluminizing thereafter. Pack cementation siliconizing performed at 950C for 2, 4 and 6 hours in several powder mixtures of Si, A12O3 and NHiCl, then aluminum was diffused into the surface of the specimens by an industrial aluminizing process. The modified coatings were characterized by means of standard metallography, scanning electron microscopy, energy dispersive spectroscopy and X-ray diffraction methods. The results show that Si in the coatings mainly presents in the form of secondary phases including Cr3Si, Mo5Si3 and Nii6Ti6Si7, well distributed within the NiAl matrix. The advantages of this two stage modified coating is discussed.

Hot Corrosion Behavior of a Cr-Modified Aluminide Coating on a Ni-Based Superalloy

A Cr-modified aluminide coating is prepared on a Ni-based superalloy using arc ion plating and subsequent pack cementation aluminizing.Hot corrosion behavior of the Cr-modified aluminide coating exposed to molten Na2SO4/K2SO4（3：1） or Na2SO4/NaCl（3：1） salts at 900 °C in static air are evaluated as well as the aluminide coating.The results indicate that compared with the aluminide coating,the anti-corrosion properties of the Cr-modified aluminide coating in the both salts are improved,which should be attributed to the beneficial effect of the Cr in the coating.The corrosion mechanism of the Cr-modified aluminide coating,especially the role of Cr in the mixture salt corrosion,is discussed.

TiAl合金高温循环氧化行为及其表面改性研究

研究了TiAl金属间化合物及表面涂层在空气中的高温循环氧化行为。结果表明:在800℃时TiAl合金具有较好的抗高温氧化行为,但当温度高于800℃时,TiAl合金表面未能形成单一的Al2O3保护层,而是形成外3层为疏松的TiO2层,内层为TiO2+Al2O3的混合氧化物层,因而使得TiAl合金的抗高温循环氧化性能严重蜕化。TiAl合金经过Cr改性铝化处理后,表面形成了具有立方Ll2结构的Al67Ti26Cr7层,立方Ll2结构的Al67Ti26Cr7不仅具有较高的铝含量,而且具有优良的韧性,因而使得处理后的TiAl合金具有良好的抗高温循环氧化性能。铝化物涂层尽管有很高的铝含量,但由于铝化得到的TiAl3相具有四方形结构,涂层非常脆。

TiAl合金表面机械研磨渗铝涂层的制备及高温性能

利用机械研磨渗在TiAl合金表面制备了铝化物涂层。在600℃经过150 min的振动处理后,TiAl合金表面形成了约为30μm的涂层。该涂层均匀致密,Al和Ti元素沿涂层均匀分布。XRD分析表明该涂层的相结构为Al3 Ti相。在900℃下,经过300 h的循环氧化后,该铝化物涂层表面形成了一层连续均匀的Al2 O3膜,表现出良好的抗氧化和抗剥落性能。相比之下,TiAl合金空白样表面形成了分层结构的氧化层,主要由Al2O3和TiO2混合氧化物组成,因此表现出较差的高温性能。

γ-TiAl合金表面粉末包埋渗铝改性层的组织与高温抗氧化性能

采用粉末包埋渗金属技术在γ-TiAl合金表面制备出一层渗铝改性层,对改性层的表面形貌、元素分布规律及相组成进行了检测与分析,并试验研究了改性层在850℃静态空气中的抗氧化性能。结果表明:改性层均匀致密,无明显的贯穿裂纹,主要组成相为TiAl3;在850℃静态空气中恒温氧化100h后,表面氧化层主要由Al2O3、TiAl3、TiAl2相组成,改性层显著提高了γ-TiAl合金的高温抗氧化性能。

催化剂及Al对TiAl合金表面Si-Al-Y共渗层组织结构的影响

通过1 050℃下Si-Al-Y扩散共渗4h的方法在TiAl合金表面制备了Y改性Si-Al共渗层,采用SEM、EDS和XRD分析了渗剂中催化剂(AlCl3·6H2O)及Al含量对共渗层组织及相组成的影响。结果表明,催化剂含量为1%(质量分数)时未形成完整的Si-A-Y共渗层;当催化剂含量为3%,5%和8%(质量分数)时所形成的共渗层均具有多层复合结构,共渗层的内层都是由TiAl2和γ-TiAl相组成,互扩散区为富Al的TiAl相;随催化剂含量的增加共渗层外层和中间层的相组成都发生了改变;催化剂含量为3%(质量分数)时所制备的共渗层外层为大量的(Ti,X)5Si4(X表示元素Nb和Cr)和少量的(Ti,X)5Si3相;催化剂含量为5%,8%(质量分数)时所制备的共渗层外层分别为(Ti,X)5Si3和TiSi2相,中间层均为(Ti,X)5Si4及(Ti,X)5Si3相,由于TiSi2外层具有良好的抗高温氧化性能,因此催化剂含量为8%(质量分数)时适合用于Si-Al-Y共渗层的制备。Al含量对共渗层的相组成无显著影响,但改变了共渗层各层厚度。

粉末包埋渗铝与气氛渗铝对P92钢650℃饱和蒸汽氧化行为的影响

表面渗铝技术可以在不改变基体材料力学性能的基础上显著提高基体的抗高温蒸汽氧化性能。利用低温粉末包埋和气氛渗铝两种方法在P92钢表面制备了铝化物涂层,并结合氧化增重法、扫描电镜观察及XRD分析,研究了两种工艺下铝化物涂层的650℃饱和蒸汽氧化行为。结果表明:P92钢抗氧化能力不足,生成了由外层疏松层瘤状富铁氧化物与表面氧化膜下方内氧化物FeCr2O4组成的双层结构氧化膜,外层富铁氧化膜在氧化300 h后发生剥落;低温包埋渗铝所得涂层为β-FeAl层,氧化500 h后试样表面形成极薄的保护性α-Al2O3氧化膜(<0.2μm);气氛渗铝涂层为单层Fe3Al结构,氧化500 h后试样外表面形成了Fe3O4+Fe2O3氧化膜,厚度为1.3μm,靠近涂层表面生成单层连续Al2O3氧化膜。采用低温包埋和气氛渗铝均可提升P92钢的抗蒸汽氧化能力。

CLAM钢表面铝化物涂层的制备与铅液相容性研究

目的探索铝化物涂层的制备工艺,研究其是否能有效抑制铅液对CLAM钢的腐蚀。方法用配制的渗剂对CLAM钢进行包埋渗铝,并通过随后的热扩散和原位氧化处理,在CLAM钢表面制备铝化物涂层,研究不同渗铝时间和热扩散时间对涂层厚度的影响。通过静态氧化试验和铅液腐蚀试验,分别评价铝化物涂层的抗氧化性能及其与铅液的相容性,采用XRD、SEM和EPMA分析涂层的相组成以及铅液腐蚀前后的微观形貌和元素分布。结果包埋渗铝+热扩散+原位氧化处理制备的铝化物涂层主要由约30μm的FeAl相层和约70μm的α-Fe(Al)固溶体层组成。在热处理过程中,由于Al和Fe的互扩散现象,涂层中的Fe-Al相依次经过了Fe_(2)Al_(5)、FeAl_(2)、FeAl、Fe_(3)Al和α-Fe(Al)的转变。在600℃空气中静态氧化120 h后,铝化物涂层试样氧化质量增量为0.028 mg/cm^(2),比CLAM钢的氧化质量增量降低了1个数量级,铝化物涂层使CLAM钢的氧化动力学曲线由直线规律转变为抛物线规律。经550℃铅液腐蚀600、1800 h后,铝化物涂层的腐蚀质量增量分别为0.058、0.077 mg/cm^(2),仅约为CLAM钢的1/120。CLAM钢表面产生了疏松多孔的铁氧化物层,而铝化物涂层没有发生明显的腐蚀,但是腐蚀1800 h后,随着表面铝含量的不断消耗,Al_(2)O_(3)层厚度逐渐减小。结论铝化物涂层具有良好的抗氧化性能及与铅液的相容性,能够有效抑制铅液对CLAM钢的腐蚀。

铝化物涂层中β-NiAl相Ni,Al互扩散系数计算

通过纯Ni和K465合金表面渗Al涂层中Al原子浓度分布曲线的分析,考虑到K465合金复杂的化学成分和显微组织,基于一定的假设,推导出Wagner修正式,并分别计算了850,950和1050℃纯Ni和K465合金表面渗Al涂层中β-NiAl相Ni,Al互扩散系数。计算结果表明:K465合金表面渗Al层中β-NiAl相Ni,Al互扩散系数明显小于纯Ni表面渗Al涂层中β-NiAl相Ni,Al互扩散系数;与化学计量比β-NiAl相相似,K465合金表面渗Al中β-NiAl相Ni,Al互扩散系数与Al原子浓度有很大的相关性,简要分析了合金元素和析出相对渗Al涂层中β-NiAl相Al,Ni互扩散系数的影响。

钼基高温合金表面包埋渗法制备渗铝层的组织与性能

采用包埋渗法在TZM钼基高温合金表面制备抗氧化的渗铝层,渗铝温度为1 050℃,渗铝时间为12 h;采用SEM、EDS和XRD等分析了渗层的显微组织、物相组成和元素分布等,并对渗层的硬度和抗高温氧化性能进行了研究。结果表明:渗层的相组成为Al_5Mo、Al_3Mo和Al_4Mo;渗层均匀致密,厚度达到130μm,具有双层结构,与基体形成了冶金结合;渗层表面呈颗粒状,其显微硬度达到了8 000 MPa;在800℃×80 h高温氧化下包埋渗铝层具有较好的抗氧化性能。

CeO2改善低温渗铝涂层抗氧化性能的研究（英文）

在Ni基体上电沉积纯Ni镀层和Ni-CeO2复合镀层并对其进行620℃低温渗铝,制备了无CeO2和CeO2改性的铝化物涂层。将以上2种涂层在1000℃下氧化,研究CeO2颗粒的加入对氧化膜的生长速率和粘附性能的影响。结果表明,在δ-Ni2Al3涂层中加入纳米CeO2颗粒可以推迟一层完整α-Al2O3膜的形成时间,降低氧化膜的生长速率。此外,纳米CeO2颗粒的加入提高了氧化膜的粘附性。原因是与没有CeO2掺杂的涂层相比,CeO2改性铝化物涂层在氧化膜/涂层界面上形成的空洞尺寸较小。