Investigation of Element Effect on High Temperature Oxidation of HVOF NiCoCrAlX Coatings

MCrAlX (M: Ni or Co or both, X: minor elements) coatings have been widely used to protect hot components in gas turbines against oxidation and hot corrosion at high temperatures. Understanding the influence of the X-elements on oxidation behaviour is important in the design of durable MCrAlX coatings. In this study, NiCoCrAlX coatings doped with Y+Ru and Ce, respectively, were deposited on Inconel-792 substrate by HVOF. The samples were subjected to isothermal oxidation test in laboratory air at 9000, 1000, 1100 ºC and cyclic oxidation test between 100 ºC and 1100 ºC with 1 hour dwell time at 1100 ºC. It was observed that the coating with Ce shows a much higher oxidation rate than the coating with Y+Ru under both isothermal and cyclic oxidation tests. Besides, β-depletion due to interdiffusion between coating and substrate was significantly lower with Ru addition. Simulations results using both a moving phase boundary model and an established oxidation-diffusion model show that Ru stabilize β grains which reduces β-depletion of coating due to substrate interdiffusion. This paper presents a comprehensive study of the influence of Ce and Ru on oxidation behaviour including investigation of the microstructure evolution influenced by oxidation time at coating surface and coating-substrate interface combining experiment and simulation results.