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Oxidation and Hot Corrosion Behavior of Plasma-Sprayed MCrAlY–Cr2O3 Coatings

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Abstract

The oxidation and hot corrosion behavior of two atmospheric plasma-sprayed NiCoCrAlY–Cr2O3 and CoNiCrAlY–Cr2O3 coatings, which are primarily designed for wear applications at high temperature, were investigated in this study. The two coatings were exposed to air and molten salt (75%Na2SO4–25%NaCl) environment at 800 °C under cyclic conditions. Oxidation and hot corrosion kinetic curves were obtained by thermogravimetric technique. X-ray diffraction analysis and scanning electron microscopy with energy-dispersive x-ray spectrometry were employed to characterize the coatings’ microstructure, surface oxides, and composition. The results showed that both coatings provided the necessary oxidation resistance with oxidation rates of about 1.03 × 10−2 and 1.36 × 10−2 mg/cm2 h, respectively. The excellent oxidation behavior of these two coatings is attributed to formation of protective (Ni,Co)Cr2O4 spinel on the surface, while as-deposited Cr2O3 in the coatings also acted as a barrier to diffusion of oxidative and corrosive substances. The greater presence of Co in the CoNiCrAlY–Cr2O3 coating restrained internal diffusion of sulfur and slowed down the coating’s degradation. Thus, the CoNiCrAlY–Cr2O3 coating was found to be more protective than the NiCoCrAlY–Cr2O3 coating under hot corrosion condition.

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Acknowledgment

The authors are grateful for financial support from the National Natural Science Foundation of China (Grant No. 51471159).

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Correspondence to Weigang Zhang.

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Zhang, T., Huang, C., Lan, H. et al. Oxidation and Hot Corrosion Behavior of Plasma-Sprayed MCrAlY–Cr2O3 Coatings. J Therm Spray Tech 25, 1208–1216 (2016). https://doi.org/10.1007/s11666-016-0433-5

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  • DOI: https://doi.org/10.1007/s11666-016-0433-5

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