Effect of Pack Cementation Process on Microstructure and Oxidation Behavior of Al–Si Co-deposition Coatings on Nickel Chrome Substrate
摘要
This study investigates the effect of pack cementation processes on the co-deposited Al–Si coatings on Ni–Cr alloy. The coatings were produced at temperatures of 800 °C, 900 °C, and 1000 °C, with holding times of 2, 4, and 5 hours, respectively, to achieve similar coating thicknesses. The coating’s phases and microstructure were analyzed using XRD, FE-SEM/EDS, and TEM techniques. Co-deposition of Al and Si resulted in multilayered coating structures influenced by the relative activities and diffusion kinetics of Al and Si during various pack cementation processes. Isothermal oxidation tests were performed at 1000 °C for 100 hours. The coating processed at 800 °C resulted in a non-protective, discontinuous oxide structure, while coatings processed at temperatures exceeding 800 °C produced continuous protective Al2O3 scales. The sample processed at 900 °C exhibited a denser and thinner oxide layer than the sample processed at 1000 °C, characterized by the lowest oxidation rate of 1.828 × 10−11 g2/(cm4s). The enhanced oxidation resistance of the sample at 900 °C is due to the diffusion-controlled growth of Al-rich aluminide phases, facilitating the development of a stable, interlocking Al2O3 scale with improved adhesion. The mechanism in relation to pack cementation temperature and holding time is further examined.