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Analysis and evolution on diffusional stability of nickel aluminide bond coat via nickel electro-plating

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Abstract

Aircraft and aero-engine applications have manipulated nickel aluminide coatings for their corrosion resistance and oxidation resistance in high-temperature thermal barrier coatings. The purpose of this investigation is to develop a novel diffusion barrier pure Al-rich β-NiAl bond coat. To coat the K-403 superalloy substrate, both with and without a pre-electro-deposited nickel layer, aluminide coatings are deposited using in situ chemical vapor deposition (CVD). The material characterization techniques, scanning electron microscopy, energy-dispersive spectroscopy and X-ray diffraction patterns have revealed double-layered structure, outer-layer Al-rich β-NiAl and inner inter-diffusion zone. The outer-layer β-NiAl coatings formed onto the K-403 superalloy substrate is hyper-stoichiometric aluminum rich 44.76 at% Al without nickel coating. It was found that the inter-diffusion zone (IDZ) had a thickness of about 8 µm. The alloying element concentration increases steadily from exterior to the interior of the coating’s depth and develops impure Al-rich β-NiAl coatings. On the contrary, the outer-layer β-NiAl coatings formed onto the K-403 superalloy substrate are hyper-stoichiometric aluminum-rich 44.92 at% Al with nickel coating. It was found that the inter-diffusion zone (IDZ) had a thickness of about 3 µm. The Al-rich β-NiAl phase formed at the surface of the aluminized substrate is pure because nickel-deposited layer constrained the depletion of substrate.

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Acknowledgements

Irfan Ali Abro (PhD Scholar) is highly thankful and grateful to NED University of Engineering and Technology, Karachi, Pakistan, for generous support and facilities of this research work.

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  1. School of Material Science and Engineering, Bei**g Institute of Technology, Bei**g, China

    Irfan Ali Abro

  2. Department of Materials Engineering, NED University of Engineering and Technology, Karachi, Pakistan

    Irfan Ali Abro & Ali Dad Chandio

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  1. Irfan Ali Abro
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Correspondence to Irfan Ali Abro.

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Abro, I.A., Chandio, A.D. Analysis and evolution on diffusional stability of nickel aluminide bond coat via nickel electro-plating. Eur. Phys. J. Plus 138, 229 (2023). https://doi.org/10.1140/epjp/s13360-023-03816-6

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