Hostname: page-component-cd9895bd7-jn8rn Total loading time: 0 Render date: 2024-12-21T16:06:45.796Z Has data issue: false hasContentIssue false
  • English
  • Français

Comparative evaluation of hot corrosion resistance of nanostructured AlCrN and TiAlN coatings on cobalt-based superalloys

Published online by Cambridge University Press:  25 March 2018

Raghubeer Singh Bangari ,
Sandeep Sahu  and
Prabhat Chand Yadav
Raghubeer Singh Bangari*
Affiliation:
Department of Mechanical Engineering, Indian Institute of Technology Kanpur, Kanpur-208016, India
Sandeep Sahu*
Affiliation:
Department of Materials Science and Engineering, Indian Institute of Technology Kanpur, Kanpur-208016, India
Prabhat Chand Yadav*
Affiliation:
Department of Materials Science and Engineering, Indian Institute of Technology Kanpur, Kanpur-208016, India
*
a)Address all correspondence to these authors. e-mail: raghubeersinghbangari@gmail.com, raghusb@iitk.ac.in
b)e-mail: ssandy@iitk.ac.in
c)e-mail: yadav@iitk.ac.in
Get access

Abstract

Molten vanadate-induced hot corrosion is the major cause of failure of superalloys which are generally used at higher temperatures (such as in internal combustion engines, gas turbines, high temperature tooling and dies, and petrochemical industries and marines). This effect can be minimized by applying thermally stable coatings over the superalloy. In this aspect, the current work investigates the effect of nanostructured aluminum chromium nitride (AlCrN) and titanium aluminum nitride (TiAlN) coatings on the hot corrosion behavior of Co-based superalloy, Superco-605, in an aggressive environment of Na2SO4–60% V2O5 (ratio by weight) at 700 °C up to 80 cycles. Each cycle consisted of 1 h heating at 700 °C followed by 20 min cooling in an ambient temperature. Hot corrosion kinetics was studied using the thermogravimetric technique and found to follow the parabolic rate law. The corrosion surface morphology and phases formed during hot corrosion were studied using field emission scanning electron microscopy equipped with energy dispersive spectroscopy and X-ray diffraction techniques. It was found that AlCrN coating had a better hot corrosion resistance than TiAlN coating.

Keywords

protective coatinghot corrosionmolten saltSuperco-605
Type
Article
Information
Journal of Materials Research , Volume 33 , Issue 8 , 27 April 2018 , pp. 1023 - 1031
Copyright
Copyright © Materials Research Society 2018 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

Footnotes

Contributing Editor: Jürgen Eckert

References

REFERENCES

Goyal, G., Singh, H., and Prakash, S.: Effect of superficially applied ZrO2 inhibitor on the high temperature corrosion performance of some Fe-, Co- and Ni-base superalloys. Appl. Surf. Sci. 254, 6653 (2008).CrossRefGoogle Scholar
Goward, G.W.: Protective coatings—Purpose, role, and design. Mater. Sci. Technol. 2, 194 (1986).CrossRefGoogle Scholar
Pettit, F., Giggins, C., Sims, C., Stollof, N., and Hagel, W.: Hot corrosion, Ch. 12. In Superalloys II: High-Temperature Materials for Aerospace and Industrial Power, Sims, C.T., Stoloff, N.S., and Hagel, W.C., eds. (John Wiley & Sons, Ann Arbor, Michigan, 1987), pp. 327–358.Google Scholar
Rapp, R.A. and Zhang, Y-S.: Hot corrosion of materials: Fundamental studies. JOM 46, 47 (1994).CrossRefGoogle Scholar
Sidhu, T.S., Agrawal, R.D., and Prakash, S.: Hot corrosion of some superalloys and role of high-velocity oxy-fuel spray coatings—A review. Surf. Coat. Technol. 198, 441 (2005).CrossRefGoogle Scholar
Sidhu, T.S., Prakash, S., and Agrawal, R.D.: Hot corrosion performance of a NiCr coated Ni-based alloy. Scr. Mater. 55, 179 (2006).CrossRefGoogle Scholar
Yoshiba, M.: Effect of hot corrosion on the mechanical performances of superalloys and coating systems. Corros. Sci. 35, 1115 (1993).CrossRefGoogle Scholar
Yoshiba, M., Abe, K., Aranami, T., and Harada, Y.: High-temperature oxidation and hot corrosion behavior of two kinds of thermal barrier coating systems for advanced gas turbines. J. Therm. Spray Technol. 5, 259 (1996).CrossRefGoogle Scholar
Eliaz, N., Shemesh, G., and Latanision, R.M.: Hot corrosion in gas turbine components. Eng. Fail. Anal. 9, 31 (2002).CrossRefGoogle Scholar
Bose, S.: High Temperature Coatings (Elsevier Science, Cambridge, Massachusetts, 2011).Google Scholar
Sidhu, T., Prakash, S., and Agrawal, R.: Hot corrosion resistance of high-velocity oxyfuel sprayed coatings on a nickel-base superalloy in molten salt environment. J. Therm. Spray Technol. 15, 387 (2006).CrossRefGoogle Scholar
Jegadeeswaran, N., Udaya Bhat, K., and Ramesh, M.R.: Improving hot corrosion resistance of cobalt based superalloy (Superco-605) using HVOF sprayed oxide alloy powder coating. Trans. Indian Inst. Met. 68, 309 (2015).CrossRefGoogle Scholar
Sidhu, T.S., Prakash, S., and Agrawal, R.D.: A comparative study of hot corrosion resistance of HVOF sprayed NiCrBSi and Stellite-6 coated Ni-based superalloy at 900 °C. Mater. Sci. Eng., A 445, 210 (2007).CrossRefGoogle Scholar
Lee, J-H., Tsai, P-C., and Lee, J-W.: Cyclic oxidation behavior and microstructure evolution of aluminized, Pt-aluminized high velocity oxygen fuel sprayed CoNiCrAlY coatings. Thin Solid Films 517, 5253 (2009).CrossRefGoogle Scholar
Gao, W. and Li, Z.: Nano-structured alloy and composite coatings for high temperature applications. Mater. Res. 7, 175 (2004).CrossRefGoogle Scholar
Vincenzini, P.: Zirconia thermal barrier coatings for engine applications. Ind. Ceram. 10, 113 (1990).Google Scholar
Knotek, O., Atzor, M., Barimani, A., and Jungblut, F.: Development of low temperature ternary coatings for high wear resistance. Surf. Coat. Technol. 42, 21 (1990).CrossRefGoogle Scholar
Hasegawa, H. and Suzuki, T.: Effects of second metal contents on microstructure and micro-hardness of ternary nitride films synthesized by cathodic arc method. Surf. Coat. Technol. 188, 234 (2004).CrossRefGoogle Scholar
Reiter, A.E., Derflinger, V.H., Hanselmann, B., Bachmann, T., and Sartory, B.: Investigation of the properties of Al1−xCrxN coatings prepared by cathodic arc evaporation. Surf. Coat. Technol. 200, 2114 (2005).CrossRefGoogle Scholar
Jindal, P.C., Santhanam, A.T., Schleinkofer, U., and Shuster, A.F.: Performance of PVD TiN, TiCN, and TiAlN coated cemented carbide tools in turning. Int. J. Refract. Met. Hard Mater. 17, 163 (1999).CrossRefGoogle Scholar
Kawate, M., Kimura Hashimoto, A., and Suzuki, T.: Oxidation resistance of Cr1−xAlxN and Ti1−xAlxN films. Surf. Coat. Technol. 165, 163 (2003).CrossRefGoogle Scholar
Deb, D., Iyer, S.R., and Radhakrishnan, V.M.: A comparative study of oxidation and hot corrosion of a cast nickel base superalloy in different corrosive environments. Mater. Lett. 29, 19 (1996).CrossRefGoogle Scholar
Rocca, E., Steinmetz, P., and Moliere, M.: Revisiting the inhibition of vanadium-induced hot corrosion in gas turbines. ASME. J. Eng. Gas Turbines Power 125, 664 (2003).Google Scholar
Strauss, B.M. and Putatunda, S.K.: Quantitative methods in fractography. In Proceedings of the Symposium on Evaluation and Techniques in Fractography, 10 Nov 1988 (ASTM, Atlanta, GA, 1990).Google Scholar
Stringer, J.: High temperature corrosion in practical systems. J. Phys. IV 3, 43 (1993).Google Scholar
Wright, I.G. and Gibbons, T.B.: Recent developments in gas turbine materials and technology and their implications for syngas firing. Int. J. Hydrogen Energy 32, 3610 (2007).CrossRefGoogle Scholar
Stein, K.J., Schorr, B.S., and Marder, A.R.: Erosion of thermal spray MCr–Cr3C2 cermet coatings. Wear 224, 153 (1999).CrossRefGoogle Scholar
Higuera Hidalgo, V., Belzunce Varela, J., Carriles Menéndez, A., and Poveda Martı́nez, S.: High temperature erosion wear of flame and plasma-sprayed nickel–chromium coatings under simulated coal-fired boiler atmospheres. Wear 247, 214 (2001).CrossRefGoogle Scholar
Prakash, S., Puri, D., and Singh, H.: Hot corrosion behaviour of plasma sprayed coatings on a Ni-based superalloy in Na2SO4–60% V2O5 environment. ISIJ Int. 45, 886 (2005).CrossRefGoogle Scholar
Tewari, S.N.: Investigation of hot corrosion on some Fe, Ni and Co based superalloy in Na2SO4-V2O5 environment under cyclic conditions. Ph.D. thesis, University of Roorkee, India, 1997.Google Scholar
Gitanjaly, , Prakash, S., and Singh, S.: Effects of MgO and CaO on hot corrosion of Fe base superalloy Superfer 800H in Na2SO4–60% V2O5 environment. Br. Corros. J. 37, 56 (2002).CrossRefGoogle Scholar
Sidhu, T.S., Prakash, S., and Agrawal, R.D.: Performance of high-velocity oxyfuel-sprayed coatings on an Fe-based superalloy in Na2SO4–60% V2O5 environment at 900 °C Part I: Characterization of the coatings. J. Mater. Eng. Perform. 15, 122 (2006).CrossRefGoogle Scholar
Sidhu, T.S., Prakash, S., and Agrawal, R.D.: Performance of high-velocity oxyfuel-sprayed coatings on an Fe-based superalloy in Na2SO4–60% V2O5 environment at 900 °C part II: Hot corrosion behavior of the coatings. J. Mater. Eng. Perform. 15, 130 (2006).CrossRefGoogle Scholar
Kamal, S., Jayaganthan, R., Prakash, S., and Kumar, S.: Hot corrosion behavior of detonation gun sprayed Cr3C2–NiCr coatings on Ni and Fe-based superalloys in Na2SO4–60%V2O5 environment at 900 °C. J. Alloys Compd. 463, 358 (2008).CrossRefGoogle Scholar
Chim, Y.C., Ding, X.Z., Zeng, X.T., and Zhang, S.: Oxidation resistance of TiN, CrN, TiAlN and CrAlN coatings deposited by lateral rotating cathode arc. Thin Solid Films 517, 4845 (2009).CrossRefGoogle Scholar
Chawla, V., Chawla, A., Mehta, Y., Puri, D., Prakash, S., and Sidhu, B.S.: Investigation of properties and corrosion behaviour of hard TiAlN and AlCrN PVD thin coatings in the 3 wt% NaCl solution. J. Aust. Ceram. Soc. 47, 48 (2011).Google Scholar
Mudgal, D., Ahuja, L., Bhatia, D., Singh, S., and Prakash, S.: High temperature corrosion behaviour of superalloys under actual waste incinerator environment. Eng. Fail. Anal. 63, 160 (2016).CrossRefGoogle Scholar
Mudgal, D., Ahuja, L., Singh, S., and Prakash, S.: Evaluation of corrosion performance of Superni 600 hung in secondary chamber of medical waste incinerator operating at 1050 °C. Mater. High Temp. 34, 45 (2017).CrossRefGoogle Scholar
Hurdus, M.H., Tomlinson, L., and Titchmarsh, J.M.: Observation of oscillating reaction rates during the isothermal oxidation of ferritic steels. Oxid. Met. 34, 429 (1990).CrossRefGoogle Scholar
Sadique, S.E., Mollah, A.H., Islam, M.S., Ali, M.M., Megat, M.H.H., and Basri, S.: High-temperature oxidation behavior of iron–chromium–aluminum alloys. Oxid. Met. 54, 385 (2000).CrossRefGoogle Scholar
Choi, H., Yoon, B., Kim, H., and Lee, C.: Isothermal oxidation of air plasma spray NiCrAlY bond coatings. Surf. Coat. Technol. 150, 297 (2002).CrossRefGoogle Scholar
Wang, Q.M., Wu, Y.N., Ke, P.L., Cao, H.T., Gong, J., Sun, C., and Wen, L.S.: Hot corrosion behavior of AIP NiCoCrAlY(SiB) coatings on nickel base superalloys. Surf. Coat. Technol. 186, 389 (2004).CrossRefGoogle Scholar
Klein, L., Bauer, A., Neumeier, S., Göken, M., and Virtanen, S.: High temperature oxidation of γ/γ′-strengthened Co-base superalloys. Corros. Sci. 53, 2027 (2011).CrossRefGoogle Scholar
Hebsur, M. and Miner, R.: High temperature isothermal and cyclic oxidation behavior of a single crystal Ni base superalloy. J. Mater. Energy Syst. 8, 363 (1987).CrossRefGoogle Scholar
Mahesh, R.A., Jayaganthan, R., and Prakash, S.: A study on hot corrosion behaviour of Ni–5Al coatings on Ni- and Fe-based superalloys in an aggressive environment at 900 °C. J. Alloys Compd. 460, 220 (2008).CrossRefGoogle Scholar
Singh, H., Puri, D., and Prakash, S.: Corrosion behavior of plasma-sprayed coatings on a Ni-base superalloy in Na2SO4–60% V2O5 environment at 900 °C. Metall. Mater. Trans. A 36, 1007 (2005).CrossRefGoogle Scholar
Tiwari, S. and Prakash, S.: Hot corrosion behaviour of an iron-base superalloy in salt environment at elevated temperatures. In Proceedings of Symposium Metals and Materials Research (Indian Institute of Technology Madras, Madras, 1996); p. 4.Google Scholar
Fryburg, G.C., Kohl, F.J., Stearns, C.A., and Fielder, W.L.: Chemical reactions involved in the initiation of hot corrosion of B-1900 and NASA-TRW VIA. J. Electrochem. Soc. 129, 571 (1982).CrossRefGoogle Scholar
Seiersten, M. and Kofstad, P.: The effect of SO3 on vanadate-induced hot corrosion. High Temp. Technol. 5, 115 (1987).CrossRefGoogle Scholar
Kamal, S., Jayaganthan, R., and Prakash, S.: Evaluation of cyclic hot corrosion behaviour of detonation gun sprayed Cr3C2–25%NiCr coatings on nickel- and iron-based superalloys. Surf. Coat. Technol. 203, 1004 (2009).CrossRefGoogle Scholar
Heath, G., Heimgartner, P., Irons, G., Miller, R.D., and Gustafsson, S.: An assessment of thermal spray coating technologies for high temperature corrosion protection. Mater. Sci. Forum 251, 809 (1997).CrossRefGoogle Scholar
Singh, H., Puri, D., and Prakash, S.: High temperature oxidation behaviour of plasma sprayed NiCrAlY coatings on Ni-based superalloys in air. Trans. Indian Inst. Met. 59, 215 (2005).Google Scholar
Ding, X-z., Tan, A., Zeng, X., Wang, C., Yue, T., and Sun, C.: Corrosion resistance of CrAlN and TiAlN coatings deposited by lateral rotating cathode arc. Thin Solid Films 516, 5716 (2008).CrossRefGoogle Scholar
Almeraya-Calderon, F., Martinez-Villafañe, A., and Gonzalez-Rodriguez, J.: Electrochemical studies of hot corrosion of type 347H stainless steel. Br. Corros. J. 33, 288 (1998).CrossRefGoogle Scholar
Cuevas-Arteaga, C., Uruchurtu-Chavarı́n, J., Porcayo-Calderon, J., Izquierdo-Montalvo, G., and Gonzalez, J.: Study of molten salt corrosion of HK-40 m alloy applying linear polarization resistance and conventional weight loss techniques. Corros. Sci. 46, 2663 (2004).CrossRefGoogle Scholar
Cho, S-H., Hur, J-M., Seo, C-S., Yoon, J-S., and Park, S-W.: Hot corrosion behavior of Ni-base alloys in a molten salt under an oxidizing atmosphere. J. Alloys Compd. 468, 263 (2009).CrossRefGoogle Scholar
Kolta, G.A., Hewaidy, I.F., and Felix, N.S.: Reactions between sodium sulphate and vanadium pentoxide. Thermochim. Acta 4, 151 (1972).CrossRefGoogle Scholar
Otero, E., Merino, M., Pardo, A., Biezma, M., and Buitrago, G.: Study on corrosion products of IN 657 alloy in molten salts. Key Eng. Mater. 20, 3583 (1987).Google Scholar