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Abstract <p>The influence of B content (0, 0.25, 0.5, and 1.5 wt.%) on the oxidation behavior of GH3044 superalloy is investigated at 900°C in air for up to 100&#xa0;h, and the optimized composition is used as laser cladding feedstock to produce coatings on GH3044 substrate. Increasing B causes grain refinement at 0.25–0.5 wt.% and coarsening at 1.5 wt.%. All alloys exhibit parabolic oxidation kinetics, with the lowest rate constant at 0.5 wt.% B, forming a dense and adherent oxide scale. In laser cladding, the optimized 0.5 wt.% B alloy generates a compact, crack-free coating with strong metallurgical bonding, consisting mainly of γ-Ni, (Ni, Cr, Fe), FeB<sub>2</sub>O<sub>7</sub>,&#xa0;and Al<sub>2</sub>SiO<sub>5</sub>. Increasing laser power promotes grain refinement and densification, improving hardness and reducing crack depth from 134&#xa0;µm (700 W) to 85&#xa0;µm (900 W). Thermal shock testing further confirms delayed crack initiation and reduced propagation. These findings highlight that controlled B addition improves oxidation resistance and coating durability, delivering a robust strategy to prolong the service life of high-temperature Ni-based superalloy components.</p> Graphic Abstract <p></p> Impact statement <p>Enhancing the high-temperature oxidation resistance of Ni-based superalloys is crucial for extending the service life and operational reliability of aeroengine components. This study demonstrates that trace boron engineering provides a powerful and controllable approach to tune oxidation behavior by refining microstructure, suppressing elemental segregation, and stabilizing the growth of protective oxide scales. An optimal boron content of 0.5 wt.% is identified, yielding a dense, adherent, and spallation-resistant oxide film at 900°C, markedly outperforming the pristine GH3044 alloy. Importantly, by translating this optimized composition into laser cladding, we further achieve crack-free, metallurgically bonded coatings with exceptional thermal shock durability. This study provides fundamental mechanistic insight into the boron-driven oxidation control and establishes a practical, scalable pathway to improve the high-temperature durability of Ni-based superalloys. By bridging alloy design, oxidation mechanisms, and surface engineering, this study offers a generalizable strategy for tailoring oxidation resistance through trace-element-guided microstructural engineering.</p>

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Tuning oxidation resistance of nickel-based superalloy via boron addition: Insights from laser cladding coatings

  • 期刊论文

  • 发表日期：

    2026年6月3日

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  • Yuhang Yu,
  • Chunhui Xu,
  • Chuanhui Zhang,
  • Shuo Huang,
  • Hongyun Jin

摘要

Abstract

The influence of B content (0, 0.25, 0.5, and 1.5 wt.%) on the oxidation behavior of GH3044 superalloy is investigated at 900°C in air for up to 100 h, and the optimized composition is used as laser cladding feedstock to produce coatings on GH3044 substrate. Increasing B causes grain refinement at 0.25–0.5 wt.% and coarsening at 1.5 wt.%. All alloys exhibit parabolic oxidation kinetics, with the lowest rate constant at 0.5 wt.% B, forming a dense and adherent oxide scale. In laser cladding, the optimized 0.5 wt.% B alloy generates a compact, crack-free coating with strong metallurgical bonding, consisting mainly of γ-Ni, (Ni, Cr, Fe), FeB2O7, and Al2SiO5. Increasing laser power promotes grain refinement and densification, improving hardness and reducing crack depth from 134 µm (700 W) to 85 µm (900 W). Thermal shock testing further confirms delayed crack initiation and reduced propagation. These findings highlight that controlled B addition improves oxidation resistance and coating durability, delivering a robust strategy to prolong the service life of high-temperature Ni-based superalloy components.

Graphic Abstract

Impact statement

Enhancing the high-temperature oxidation resistance of Ni-based superalloys is crucial for extending the service life and operational reliability of aeroengine components. This study demonstrates that trace boron engineering provides a powerful and controllable approach to tune oxidation behavior by refining microstructure, suppressing elemental segregation, and stabilizing the growth of protective oxide scales. An optimal boron content of 0.5 wt.% is identified, yielding a dense, adherent, and spallation-resistant oxide film at 900°C, markedly outperforming the pristine GH3044 alloy. Importantly, by translating this optimized composition into laser cladding, we further achieve crack-free, metallurgically bonded coatings with exceptional thermal shock durability. This study provides fundamental mechanistic insight into the boron-driven oxidation control and establishes a practical, scalable pathway to improve the high-temperature durability of Ni-based superalloys. By bridging alloy design, oxidation mechanisms, and surface engineering, this study offers a generalizable strategy for tailoring oxidation resistance through trace-element-guided microstructural engineering.