Synthesis and Compression Property of Oxidation-Resistant Ni-Al Foams

Three different Ni-Al foams were synthesized by vapor aluminizing with control of aluminizing time. Oxidation tests under 1100 ℃ and compression tests were conducted to evaluate the oxidation resistance and compression properties of the foams. X-ray diffraction(XRD), scanning electron microscopy(SEM), and energy-dispersive spectroscopy(EDS)tests were carried out to study the phase composition and microstructure of Ni-Al foams before and after oxidation. Results showed that vapor aluminizing process did not change the foam macro-and microstructure, and the phase composition became from β/γ'-phase to single β-phase as the aluminizing time extending. The Ni-Al foams possessed excellent oxidation resistance, and decreased A1 content increased oxidation weight gain and altered oxidation products. Foams containing single β-phase presented obvious brittleness under compression tests, but the foam with β/γ'-phase exhibited elasticity and toughness to a certain extent. The elasticity and toughness of the foams significantly can be improved after oxidation because of the phase changing in matrix during oxidation, and the pre-oxidized high-Al-content Ni-Al foams exhibited good compression properties, as well as excellent oxidation resistance.     

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℃ and 1050℃ in several mixtures of Ti, Al2O3 and NH4Cl. At the second stage,aluminum diffused into surface of the specimens by an industrial aluminizing process known as Elcoatl01(4 hrs at 1050℃). 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 A167CrsTias. Titanium modified coatings grew with a mechanism similar to simple aluminizing; this includes inward diffusion of A1 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.     

Effect of a direct magnetic field on the interfacial microstructure between molten aluminium and solid iron

Many processing techniques, such as hot dip aluminizing, bimetal formation, liquid metal corrosion, cementing, welding and diffusion bonding, are basically dependent on interfacial reactions [1-3]. It is therefore important to investigate the formation and growth of intermetallic layers at the interface. There have been several studies carried out to examine chemical compositions and growth kinetics of intermetallic layers in the Al-Fe system [4-9]. Most authors have come to an agreement that…     

PROPERTIES OF YTTRALUMINIZING COATING ON Ni-BASE SUPERALLOYS

The yttraluminizing coating on the Ni-base superalloys has been developed by dipping thespecimens in a specially made yttrium-containing slurry as an underlayer and over spraying aCr-Al slurry as a protective layer,then heating to 1060℃ and holding for 1 h under argonatmosphere.Analysis by EPMA showed that the yttrium was concentrated in the intermediatezone of the coating as metallic compound Ni-5Y.After exposure to air up to 1000℃,theoxidation test revealed that the anti-oxidation resistance of the yttraluminizing coating withpost-aluminizing is much superior to that with single aluminizing only.     

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.     

The Effect of NiAI Coatings on Oxidation Behavior of AISI 403 Stainless Steel

This paper reports the oxidation behavior of stainless steel type 403 as a substrate material with and without NiAl coating. Evaluation of oxidation resistance was performed on uncoated and coated specimens at 850 and 1050℃. Acommercial diffusion process was used for the formation of NiA1 intermetallic coatings on the specimens. Before aluminizing, a layer of nickel, about 40μm, was deposited on specimens by electroplating. Various techniques including SEM, EDAX, optical microscopy and micro-hardness testing were employed to investigate the coatings before and after oxidation tests. Nickel-aluminides produced by two stage; plating-aluminizing, treatment with NiA1 on the surface increased the performance of stainless steel samples significantly.     

Effect of rare earth （RE） on diffusion of aluminum atoms in aluminizing

The RE-aluminized coating and pure aluminized coating on 20 carbons steel were prepared by hot dip aluminizing method at 740 ℃. After diffusion treatment at 850 ℃for 4 h, the distribution of aluminum and lanthanum elements in the coating was analyzed with energy disperse spectroscopy（EDS） and electron probe microanalyses（EPMA）, and the lattice parameter ofa-Fe in the matrix of the coating was measured precisely by X-ray diffractometer（XRD）. The results show that RE permeates into the aluminized coating, leads to lattice disturbance and increases the depth of the aluminized coating. On the basis of the results, the expression of the diffusion coefficient of Al atoms is derived from the diffusion flow, and the effect of the high vacancy concentration and high concentration gradient of vacancies on the diffusion of Al atoms was analyzed by establishing the kinetics model of the vacancy mechanism of diffusion. The results show that the high vacancy concentration and high concentration gradient of vacancies in the RE-aluminized processes are the main reason why the diffusion coefficient of Al atoms in RE-aluminizing is bigger than that in pure aluminizing.     

The Effect of La on the Microstructure and Corrosion-resistance of Hot-dipped Aluminizing Steel

THE HOT-DIPPED ALUMINUM technology of metalsurface is a traditional technology of surfacedisposal[1|21adding some rare-earth during thehot-dipped aluminum process can effect the technologyof hot-dipped aluminum and the microstructure ofhot-dipped aluminizing layer'31,so the surfacecapability of metal is greatly increased,forming a newtechnology of hot-dipped aluminum.After hot-dippedaluminum steel,metal surface has excellent corrosionresistance,high temperature oxidation,especiallycorro…     

OXIDATION RESISTANCE OF NANOCRYSTAL ODS ALUMINIDE COATINGS PRODUCED BY PACK ALUMNIZING PROCESS ASSISTED BY BALL PEENING

Nanocrystal ODS (oxide dispersion strengthening) aluminide coatings were produced on a stainless steel and nickel-based superalloy by the pack aluminizing process assisted by ball peening. Pure Al powders and 1% of ultra-fine Y2O3 powders were mixed by ball milling. The ultra-fine Y2O3 powders were dispersed in Al particles. Ball peening welded the Al particles onto the substrate and accelerated the formation of aluminide coating, Nanocrystal ODS aluminide coatings were produced by the outward growth at a much low temperature (below 600℃) in a short treatment time. The effects of the operation temperature and treatment time on the formation of the coatings were analyzed. SEM (scanning electron microscope), AFM (atomic force microscope), EDS (energy dispersive X-ray spectroscopy), XRF (X-ray fluorescence spectrometer) and XRD (X-ray diffraction) methods were applied to investigate the microstructure of the coatings. High-temperature oxidation tests were carried out to evaluate the oxidation resistance of the ODS aluminide coatings.     

Corrosion Behavior of Fe–Al Coatings Fabricated by Pack Aluminizing Method

In this study,the two kinds of Fe–Al coatings were fabricated by pack aluminizing on low-carbon steel at different temperatures.The corrosion behavior of the Fe–Al coatings in artificial seawater was investigated by the electrochemical and weight loss techniques.Results show that the thickness of coating layer increases with increasing aluminizing temperature.The coatings exhibit high micro-hardness and good metallurgical bonding with the substrate.In comparison with the steel substrate,the corrosion current density Icorrof the Fe–Al coatings is always lower than that of substrate,about 1/38 or 1/33 after 2 h immersion,and 1/3 or 1/6 for 720 h immersion.As can be seen from the weight loss curve,the Fe–Al coatings show less loss than that of the substrate within 30-day immersion.The corrosion products formed on the surface of the coatings include oxides of Al,Mg,Fe and Ca,and pitting defect has also been found.The Fe–Al coating with higher content of Fe_2Al_5 has better corrosion resistance.     

The effects of ultrasonic nanocrystal surface modification (UNSM) on pack aluminizing for the fabrication of Pt-modified aluminide coatings at low temperatures

An 8–9 μm thick Pt layer was coated on a superalloy and transformed to a Ni–Pt alloy layer by the interdiffusion of Ni and Pt at 1050 °C for 3 h. The surface of the Ni–Pt alloy layer was pack aluminized to form a Pt-modified aluminide coating. Ultrasonic nanocrystal surface modification (UNSM) was applied to the alloy layer prior to pack aluminizing. The effects of UNSM on Pt-modified aluminide coatings fabricated at 750, 850, 950, and 1050 °C were studied. The treated Ni–Pt alloy layers had finer grain sizes than the untreated specimens. In addition, UNSM made the grain size of the Ni–Pt alloy finer and reduced the surface roughness. During pack aluminizing, the Pt-modified aluminide coatings fabricated following UNSM uptook more Al and were thicker than the untreated Pt-modified aluminide coatings at the various temperatures (750, 850, 950, and 1050 °C). The untreated Pt-modified aluminide coatings with pack aluminizing performed at 750 and 850 °C were composed of only a two-phase (NiAl + PtAl₂) layer, due to insufficient diffusion of Pt at the lower temperatures. However, two-phase and one-phase (NiAl) layers were obtained in the treated Pt-modified aluminide coatings which were pack-aluminized at 750, 850, 950, and 1050 °C, due to the diffusion of Pt through the greater amount of grain boundaries and increased volume generated by UNSM before the pack aluminizing. Additionally, the treated coatings had smoother surfaces even after the pack aluminizing. During cyclic oxidation at 1150 °C for 1000 h, the treated Pt-modified aluminide coatings aluminized at relatively low temperatures (750 and 850 °C) showed better cyclic oxidation resistance than the untreated Pt-modified aluminide coating aluminized at 1050 °C.     

OXIDATION RESISTANCE OF NANOCRYSTAL ODS ALUMINIDE COATINGS PRODUCED BY PACK ALUMINIZING PROCESS ASSISTED BY BALL PEENING

Nanocrystal ODS （oxide dispersion strengthening） aluminide coatings were produced on a stainless steel and nickel-based superalloy by the pock aluminizing process assisted by ball peening, Pure Al powders and 1% of ultra-fine Y2O3 powders were mixed by ball milling. The ultra-fine Y2O3 powders were dispersed in Al particles. Ball peening welded the Al particles onto the substrate and accelerated the formation of aluminide coating. Nanocrystal ODS aluminide coatings were produced by the outward growth at a much low temperature （below 600℃） in a short treatment time. The effects of the operation temperature and treatment time on the formation of the coatings were analyzed. SEM （scanning electron microscope）, AFM （atomic force microscope）, EDS （energy dispersive X-ray spectroscopy）, XRF （X-ray fluorescence spectrometer） and XRD （X-ray diffraction） methods were applied to investigate the microstructure of the coatings. High-temperature oxidation tests were carried out to evaluate the oxidation resistance of the ODS aluminide coatings.     

Aluminide Coatings Formed on Fe–13Cr Steel at Low Temperature and its Oxidation Resistance

A novel aluminizing process has been developed to produce aluminide coatings on Fe–13Cr stainless steel at a much lower temperature (520–600 °C) and with a shorter time (60–240 min) compared to the conventional pack-aluminizing processes. In this process, chemical reaction and atomic diffusion were accelerated by ball impact generated by mechanical vibration. The effects of operation temperature and duration on the coating thickness were studied. Scanning-electron microscopy (SEM and EDS) showed that the coatings appeared to be dense, homogeneous, free of porosity and with excellent adherence to the substrate. X-ray diffraction (XRD) analyses indicated that the coatings consisted mainly of η-Fe₂Al₅ and θ-FeAl₃. High-temperature oxidation tests were carried out in air at 900 °C. The results indicated that the aluminide coatings obtained from this process have significantly improved high-temperature oxidation resistance.     

分散剂Y2O3对渗铝层的影响

通过改变传统渗剂来研究分散剂（Al2O3，Y2O3）在渗铝过程中的作用和对渗铝层的影响。利用XRD和SEM对渗层相的组成、氧化前后表面形貌进行分析。结果表明：分散剂Y2O3在最初的渗铝过程中参加了渗铝过程，不仅防止铝粉粘结，而且影响渗层相的组成。分散剂为Al2O3时，渗层主要为Al3Ti＋AlTi＋AlTi3相，而分散剂中含有Y2O3时，渗层土要为AlTi3相，这与传统渗铝机理认为分散剂在渗铝过程中不参加渗铝反应相矛盾。同时，分散剂也影响着渗铝层氧化前后的表面形貌及Al2O3的晶格类型。     

Cyclic oxidation of Pt/Pd-modified aluminide coating on a nickel-based superalloy at 1150 °C

Pt-, Pd-, and Pt/Pd-modified aluminide coatings were prepared on Inconel 738LC by pack aluminizing at 1034 °C. During pack aluminizing, Pt-modified aluminide coating formed a two-phase β-NiAl + PtAl₂ layer and a β-NiAl layer on an interdiffusion zone, whereas Pd- and Pt/Pd-modified aluminide coatings formed only the thicker β-NiAl layer. However, Pd-modified aluminide coating had many pores. During cyclic oxidation, Pt/Pd-modified aluminide coating had a surface that was less rumpled than that of Pt-modified aluminide coating due to its thicker thickness. Pt/Pd-modified aluminide coating had a 22% greater Al-uptake than Pt-modified aluminide coating. Cyclic oxidation tests at 1150 °C showed that Pt/Pd-modified aluminide coating had the best cyclic oxidation resistance. After the cyclic oxidation, an additional γ-Ni phase was seen beneath the outermost alumina scale on the the γ′-Ni₃Al phase in Pt/Pd-modified aluminide coating. The γ-Ni phase, which had a higher Cr content, increased the adhesion and stability of the alumina.     

A study on composite coatings of yttrium ion-plating and pack aluminizing for high-temperature applications

Yttrium (Y) was incorporated by an ion-plating method either before or after pack aluminizing to maximize the corrosion resistance of IN 713C. Various combinations of pack aluminizing and yttrium-ion plating were examined with respect to coating sequence, aluminum activity, and corrosive environment. Of all the various coating combinations examined, the best corrosion resistance was obtained from H/A + Y (high-activity aluminizing + Y-ion plating) type composite coatings. Uniformity of the Y deposition was greatly dependent upon the surface condition of the aluminide-coating layer. The high-activity aluminide coating gave better uniformity of Y deposition than did the low-activity-aluminide coating.Improvement of corrosion resistance by the Y-modified-aluminide composite coatings of H/A + Y type occur because the presence of Y between the Al₂O₃ columns improves Al₂O₃ scale adherence and substantially prevents depletion of Al in the aluminide-coating layer.     

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℃ and 1050℃ in several mixtures of Ti, Al2O3 and NH4Cl. 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 Al67CrsTi25. 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.     

Low-temperature processing of Fe–Al intermetallic coatings assisted by ball milling

A novel technique has been developed to produce Fe–Al intermetallic coatings on steel. This technique applies mechanical vibration to a retort, which is loaded with Al powder, alumina filler, ammonium chloride activator and FeCrAl alloy balls. The operation temperature was from 440 to 600 °C. This technique produced coatings with thickness of 17 μm for 15 min and 90 μm for 120 min treatment at 560 °C. The coatings appear to be homogeneous, with a high density and free of porosity, and have excellent adherence to the substrate. The coatings consisted mainly of η-Fe₂Al₅ with small amounts of θ-FeAl₃ and β-FeAl, and exhibited a nano-structure. Microstructure studies suggested that the formation of the intermetallic phases at a low temperature has a complex mechanism, including the formation of a thin Al layer on the substrate by ball milling; Al-rich phases nucleation, growth and formation of an initial alloy layer; severe plastic deformation which increases the local temperature and produces a nano-structure; and fast outward diffusion of Fe and formation of Fe–Al intermetallics. This technique reduced the treatment temperature and duration significantly compared with the conventional Al pack cementation processes, providing a new approach to industrial diffusion coatings with great energy and time savings.     

Y对Nb基体表面包埋渗铝涂层微观组织和生长机制的影响

通过向包埋渗铝剂中添加Y₂O₃粉末在纯Nb基体表面制备了Y改性的渗铝涂层,研究了Y对涂层微观组织和生长机制的影响。结果表明,Y对涂层的相组成和NbAl₃相的晶粒形态均无明显影响。随包埋剂中Y₂O₃添加量的增加,涂层表面的Y含量升高。Y改性后,涂层的生长机制由受Al原子的沿晶扩散控制转变为受Al原子的晶内扩散控制,降低了涂层的生长速率,并使NbAl₃相的柱状晶区形成了<010>//ND和<110>//ND的两种丝织构。     

不锈钢表面振动冲击加速渗铝工艺研究

研究了利用喷丸加速制备涂层技术,对1Cr18Ni9Ti不锈钢分别进行600℃×4、6和8 h渗铝处理,研究了1Cr18Ni9Ti试样的单位面积增重、Al涂层厚度、主要元素沿涂层截面的分布;并将不同温度下获得的铝化物涂层与空白试样一起进行了高温氧化测试实验(900℃×100 h)。结果表明,在较低的温度600℃和较短的时间4 h,可以在1Cr18Ni9Ti钢基体上形成35μm厚的铝化物涂层;但抗氧化性能测试结果却表明,振动渗制处理6 h获得的铝化物涂层性能优于处理4 h和8 h的涂层。