Review on Nickel Aluminide based Bond Coat Properties and Oxidation Performance for Thermal Barrier Coating (TBC) Application

  • Authors

    • NF. Kadir
    • A. Manap
    • M. Satgunam
    • Nurfanizan Mohd Afandi
  • Bond coat, Nickel Aluminide, Oxidation behavior, Reactive Element, Thermal Barrier Coating
  • Thermal Barrier Coating (TBC) as protective coatings are applied to maintain efficiency and prevent structural failures mainly in gas turbine system. This paper reviews on recent bond coating from Nickel aluminide bond coat with addition of Reactive Elements (RE). This paper also reviews the major concern in TBC with presence of different Reactive Element (RE) added in term of RE composition, properties and oxidation test performance. Recent studies are more focusing on few REs including Ce, Hf, La, Y and Zr based on oxidation property test results. The comparisons clearly show that ceramics addition are superior for bond coat mechanical and thermal properties improvement while RE addition such as Ce and Zr present excellent oxidation performance at 900°C and above.

  • References

    1. [1] Johari, A.D.B., Characterization and Thermophysical Properties of Multi-Layered YSZ/REZ Thermal Barrier Coating Under Heat Treatment in Department of Mechanical Engineering 2017, Universiti Tenaga Nasional p. 119.

      [2] Bobzin, K., et al., Microstructure behaviour and influence on thermally grown oxide formation of doubleâ€ceramicâ€layer EBâ€PVD thermal barrier coatings annealed at 1,300° C under ambient isothermal conditions. Materialwissenschaft und Werkstofftechnik, 2014. 45(10): p. 879-893.

      [3] Li, C.-J., et al., The correlation of the TBC lifetimes in burner cycling test with thermal gradient and furnace isothermal cycling test by TGO effects. Journal of Thermal Spray Technology, 2017. 26(3): p. 378-387.

      [4] Heuer, A.H., et al., On the growth of Al2O3 scales. Acta Materialia, 2013. 61(18): p. 6670-6683.

      [5] Beyhaghi, M., et al., Effect of powder reactivity on fabrication and properties of NiAl/Al 2 O 3 composite coated on cast iron using spark plasma sintering. Applied Surface Science, 2015. 344: p. 1-8.

      [6] Yao, J., et al., Thermal barrier coating bonded by (Al2O3–Y2O3)/(Y2O3-stabilized ZrO2) laminated composite coating prepared by two-step cyclic spray pyrolysis. Corrosion Science, 2014. 80: p. 37-45.

      [7] Wang, X., et al., The reactive element effect of ceria particle dispersion on alumina growth: A model based on microstructural observations. Sci Rep, 2016. 6: p. 29593.

      [8] Deevi, S. and V. Sikka, Nickel and iron aluminides: an overview on properties, processing, and applications. Intermetallics, 1996. 4(5): p. 357-375.

      [9] Shiomi, S., et al., Aluminide Coatings Fabricated on Nickel by Aluminium Electrodeposition from DMSO2-Based Electrolyte and Subsequent Annealing. Materials transactions, 2011. 52(6): p. 1216-1221.

      [10] Zhang, T., et al., Effects of Dy on the adherence of Al 2 O 3/NiAl interface: a combined first-principles and experimental studies. Corrosion Science, 2013. 66: p. 59-66.

      [11] Hultgren, R., et al., Selected values of the thermodynamic properties of binary alloys. 1973, National Standard Reference Data System.

      [12] Tuan, W.H. and Y.P. Pai, Mechanical Properties of Al2O3â€NiAl Composites. Journal of the American Ceramic Society, 1999. 82(6): p. 1624-1626.

      [13] Chmielewski, M., et al., Sintering behavior and mechanical properties of NiAl, Al2O3, and NiAl-Al2O3 composites. Journal of Materials Engineering and Performance, 2014. 23(11): p. 3875-3886.

      [14] Udhayabanu, V., K. Ravi, and B. Murty, Ultrafine-grained, high-strength NiAl with Al 2 O 3 and Al 4 C 3 nanosized particles dispersed via mechanical alloying in toluene with spark plasma sintering. Materials Science and Engineering: A, 2013. 585: p. 379-386.

      [15] Lin, C.-K., S.-S. Hong, and P.-Y. Lee, Formation of NiAl–Al2O3 intermetallic-matrix composite powders by mechanical alloying technique. Intermetallics, 2000. 8(9-11): p. 1043-1048.

      [16] Huang, M., et al., Multifunctional Alumina Composites with Toughening and Crackâ€Healing Features Via Incorporation of NiAl Particles. Journal of the American Ceramic Society, 2015. 98(5): p. 1618-1625.

      [17] Nosewicz, S., et al., The influence of hot pressing conditions on mechanical properties of nickel aluminide/alumina composite. Journal of Composite Materials, 2014. 48(29): p. 3577-3589.

      [18] Oleszak, D., NiAl-Al2O3 intermetallic matrix composite prepared by reactive milling and consolidation of powders. Journal of materials science, 2004. 39(16-17): p. 5169-5174.

      [19] Subhasisa Nath, I.M., Jyotsna Dutta Majumdar Studies on Mechanical and Oxidation Resistance Properties of CoNiCrAlY/Al2O3/YSZ Compositionally Graded Thermal Barrier Coating Developed by Air Plasma Spraying in Asia Thermal Spray Conference. 2014. p. 67-68.

      [20] Unocic, K.A., et al., High-temperature behavior of oxide dispersion strengthening CoNiCrAlY. Materials at High Temperatures, 2017: p. 1-12.

      [21] Evans, A.G., D.R. Clarke, and C.G. Levi, The influence of oxides on the performance of advanced gas turbines. Journal of the European Ceramic Society, 2008. 28(7): p. 1405-1419.

      [22] Navrotsky, A., et al., Thermodynamics of solid phases containing rare earth oxides. The Journal of Chemical Thermodynamics, 2015. 88: p. 126-141.

      [23] Wu, Q., et al., Effect of Hf4+Concentration on Oxygen Grain-Boundary Diffusion in Alumina. Journal of the American Ceramic Society, 2015. 98(10): p. 3346-3351.

      [24] Jarvis, E.A. and E.A. Carter, The role of reactive elements in thermal barrier coatings. Computing in Science & Engineering, 2002. 4(2): p. 33-41.

      [25] Seal, S., et al., Ceria based high temperature coatings for oxidation prevention. JOM-e, 2000. 52(1): p. 1-8.

      [26] Birks, N., G.H. Meier, and F.S. Pettit, Introduction to the high temperature oxidation of metals. 2006: Cambridge University Press.

      [27] Emily A. Jarvis, E.A.C., The role of reactive elements in Thermal Barrier Coatings. HPS and National Security, 2002.

      [28] Bouchaud, B., et al., Correlations between electrochemical mechanisms and growth of ceria based coatings onto nickel substrates. Electrochimica Acta, 2013. 88: p. 798-806.

      [29] Zhao, C., et al., Effect of alloyed Lu, Hf and Cr on the oxidation and spallation behavior of NiAl. Corrosion Science, 2017. 126: p. 334-343.

      [30] Hou, P.Y., The Reactive Element Effect – Past, Present and Future. Materials Science Forum, 2011. 696: p. 39-44.

      [31] Quazi, M.M., et al., Effect of rare earth elements and their oxides on tribo-mechanical performance of laser claddings: A review. Journal of Rare Earths, 2016. 34(6): p. 549-564.

      [32] Wang, Y., et al., The effects of ceria on the mechanical properties and thermal shock resistance of thermal sprayed NiAl intermetallic coatings. Intermetallics, 2008. 16(5): p. 682-688.

      [33] Guo, H., et al., Effect of Sm, Gd, Yb, Sc and Nd as reactive elements on oxidation behaviour of β-NiAl at 1200°C. Corrosion Science, 2014. 78: p. 369-377.

      [34] Padture, N.P., M. Gell, and E.H. Jordan, Thermal barrier coatings for gas-turbine engine applications. Science, 2002. 296(5566): p. 280-284.

      [35] Choo, H., P. Nash, and M. Dollar, Mechanical properties of NiAl–AlN–Al 2 O 3 composites. Materials Science and Engineering: A, 1997. 239: p. 464-471.

      [36] Kumar, V. and K. Balasubramanian, Progress update on failure mechanisms of advanced thermal barrier coatings: A review. Progress in Organic Coatings, 2016. 90: p. 54-82.

      [37] Daroonparvar, M., et al., Improved Thermally Grown Oxide Scale in Air Plasma Sprayed NiCrAlY/Nano-YSZ Coatings. Journal of Nanomaterials, 2013. 2013: p. 1-9.

      [38] Baskaran, T. and S.B. Arya, Role of thermally grown oxide and oxidation resistance of samarium strontium aluminate based air plasma sprayed ceramic thermal barrier coatings. Surface and Coatings Technology, 2017. 326: p. 299-309.

      [39] Brandl, W., et al., The oxidation behaviour of sprayed MCrAlY coatings. Surface and Coatings Technology, 1996. 86: p. 41-47.

      [40] Haynes, J., et al., Characterization of alumina scales formed during isothermal and cyclic oxidation of plasma-sprayed TBC systems at 1150 C. Oxidation of Metals, 1999. 52(1): p. 31-76.

      [41] Wang, H., et al., Effects of CeO2 nanoparticles on microstructure and properties of laser cladded NiCoCrAlY coatings. Journal of Rare Earths, 2010. 28(2): p. 246-250.

      [42] Mahesh, R., R. Jayaganthan, and S. Prakash, A study on the oxidation behavior of HVOF sprayed NiCrAlY–0.4 wt.% CeO 2 coatings on superalloys at elevated temperature. Materials Chemistry and Physics, 2010. 119(3): p. 449-457.

      [43] Kamal, S., R. Jayaganthan, and S. Prakash, Mechanical and microstructural characteristics of detonation gun sprayed NiCrAlY+0.4wt% CeO2 coatings on superalloys. Materials Chemistry and Physics, 2010. 122(1): p. 262-268.

      [44] Hongyu, C., et al., Effect of CeO2 on the Isothermal Oxidation of Electrode-posited Ni-Al Composite Coatings at 950 °C. Rare Metal Materials and Engineering, 2015. 44(3): p. 571-575.

      [45] He, J., et al., The role of Dy and Hf doping on oxidation behavior of two-phase (γ′+β) Ni–Al alloys. Corrosion Science, 2015. 98: p. 699-707.

      [46] Guo, H., et al., Effect of co-doping of two reactive elements on alumina scale growth of β-NiAl at 1200°C. Corrosion Science, 2014. 88: p. 197-208.

      [47] Yan, K., H. Guo, and S. Gong, High-temperature oxidation behavior of β-NiAl with various reactive element dopants in dry and humid atmospheres. Corrosion Science, 2014. 83: p. 335-342.

      [48] Wang, Y. and M. Suneson, Oxidation behavior of Hf-modified aluminide coatings on Inconel-718 at 1050 C. 2014.

      [49] Zagula-Yavorska, M., M. Wierzbińska, and J. Sieniawski, Rhodium and Hafnium Influence on the Microstructure, Phase Composition, and Oxidation Resistance of Aluminide Coatings. Metals, 2017. 7(12).

      [50] Liu, Z., et al., Cyclic oxidation resistance of Ce/Co modified aluminide coatings on nickel base superalloys. Corrosion Science, 2015. 94: p. 135-141.

      [51] Lan, H., et al., Effect of dysprosium addition on the cyclic oxidation behaviour of CoNiCrAlY alloy. Corrosion Science, 2011. 53(4): p. 1476-1483.

      [52] Hamadi, S., et al., Oxidation of a Zr-doped NiAl bondcoat thermochemically deposited on a nickel-based superalloy. Materials at High Temperatures, 2009. 26(2): p. 195-198.

      [53] Wang, X. and J.A. Szpunar, Effect of CeO2 Coating on the Isothermal Oxidation Behaviour of Ni-Based Alloy 230. Oxidation of Metals, 2017. 88(5-6): p. 565-582.

      [54] Chen, W.R., et al., Pre-oxidation and TGO growth behaviour of an air-plasma-sprayed thermal barrier coating. Surface and Coatings Technology, 2008. 202(16): p. 3787-3796.

      [55] Ahmadian, S. and E.H. Jordan, Explanation of the effect of rapid cycling on oxidation, rumpling, microcracking and lifetime of air plasma sprayed thermal barrier coatings. Surface and Coatings Technology, 2014. 244: p. 109-116.

      [56] Schumann, E., et al., High-temperature stress measurements during the oxidation of NiAl. Oxidation of metals, 2000. 53(3): p. 259-272.

  • Downloads

  • How to Cite

    Kadir, N., Manap, A., Satgunam, M., & Afandi, N. M. (2018). Review on Nickel Aluminide based Bond Coat Properties and Oxidation Performance for Thermal Barrier Coating (TBC) Application. International Journal of Engineering & Technology, 7(4.35), 624-628.