Effect of Long-term Thermal Exposure on Microstructure Evolution of Interface Thermal Barrier Coating/DZ411 Ni-based Superalloy

doi:10.11901/1005.3093.2024.026

Chinese Journal of Materials Research

2025, Vol. 39

Issue (2): 113-125 DOI: 10.11901/1005.3093.2024.026

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Effect of Long-term Thermal Exposure on Microstructure Evolution of Interface Thermal Barrier Coating/DZ411 Ni-based Superalloy

YUAN Hongyuan¹, ZHANG Siqian¹(

), WANG Dong², ZHANG Yingjian³, MA Li³, YU Minghan², ZHANG Haoyu¹, ZHOU Ge¹, CHEN Lijia¹

1 School of Material Science and Engineering, Shenyang University of Technology, Shenyang 110870, China
2 Superalloys Division, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
3 School of Materials Science and Engineering, Northeastern University, Shenyang, 110819, China

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YUAN Hongyuan, ZHANG Siqian, WANG Dong, ZHANG Yingjian, MA Li, YU Minghan, ZHANG Haoyu, ZHOU Ge, CHEN Lijia. Effect of Long-term Thermal Exposure on Microstructure Evolution of Interface Thermal Barrier Coating/DZ411 Ni-based Superalloy. Chinese Journal of Materials Research, 2025, 39(2): 113-125.

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Abstract

Herein, the effect of long term thermal exposure at 900 and 1000 ^oC on the microstructure variation of the interface MCrAlY thermal barrier coating/DZ411 Ni-based directionally solidified superalloy (IC/S)was studied by means of scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and transmission electron microscopy (TEM). The results indicate that with the extension of thermal exposure time, the substrate beneath the IC/S undergoes recrystallization, the orientation of σ-phase precipitates is 45° respect to the IC/S. Significant differences were observed in the evolution of secondary reaction zone (SRZ) and topologically close-packed (TCP) phases during heating process at 900 ^oC and 1000 ^oC. After being exposed at 900 ^oC for 100 h the granular Cr-rich phase precipitated in the interdiffusion zone (IDZ) composed of chaotically distributed γ'-phase; In contrast, IDZ and SRZ were formed after being exposed at 1000 ^oC for 100 h, and the precipitates of Cr-rich phase were not significant. After being exposed at 900 ^oC for 500 h to 2000 h, IDZ and SRZ gradually grow, and the orientation of Cr-rich phase precipitates nearby the recrystallized grain boundary with an angle 45°; However, at 1000 ^oC the Cr-rich phase precipitates and aggregates below the recrystallized grain boundary, and SRZ gradually degenerates into IDZ. The evolution of interface structure is closely related to the diffusion of elements after long-term heat exposure.

Key words: metallic materials Ni-based superalloy long-term thermal exposure interface microstructure coating/substrate interface

Received: 01 January 2024

ZTFLH:

TG 132.32

Fund: National Science and Technology Major Project(J2019-IV-0006-0074);National Science and Technology Major Project(J2019-VI-0010-0124);National Natural Science Foundation of China(52071219);Science Center for Gas Turbine Project(P2021-AB-IV-001-002)

Corresponding Authors: ZHANG Siqian, Tel: 13700022372, E-mail: sqzhang@alum.imr.ac.cn

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	Articles by authors
	YUAN Hongyuan
	ZHANG Siqian
	WANG Dong
	ZHANG Yingjian
	MA Li
	YU Minghan
	ZHANG Haoyu
	ZHOU Ge
	CHEN Lijia

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https://www.cjmr.org/EN/10.11901/1005.3093.2024.026 OR https://www.cjmr.org/EN/Y2025/V39/I2/113

Table 1 Nominal composition of experimental alloy and coating (mass fraction，%)

Fig.1 (a) cross section morphology of thermal barrier coating/alloy after spraying; (b) CSI cross-sectional morphology and elemental deposition

Table 2 The composition of each phase in the coating (mass fraction, %)

Fig. 2 BSE image of NiCoCrAlY coating/alloy cross-section after long-term thermal exposure (a) 900 ^oC-500 h; (b) 1000 ^oC-500 h; (c) 900 ^oC-4500 h; (d) 1000 ^oC-4500 h

Table 3 Element distribution in each region of Fig.2 (Al, Cr, Co, Ni, %, mass fraction)

Fig. 3 CSI cross-sectional BSE images after exposure for different time at 900 ^oC 100 h, (b) 200 h, (c) 500 h, (d) 1000 h, (e) 2000 h and (f) 4500 h

Fig.4 Original morphology (a), phase map (b), IPF image (c) and KAM image (d) of the cross-section below CSI after thermal exposure for 100 h at 900 ^oC

Fig.5 Original morphology (a), phase map (b), IPF image (c) and KAM image (d) of the cross-section below CSI after thermal exposure for 4500 h at 900 ^oC

Fig.6 TEM images and selected diffraction patterns (SAD) in the interdiffusion zone (a, b) SRZ after 1000 h of thermal exposure at 900 ^oC and (c, d) SDZ after 1000 h of thermal exposure at 1000 ^oC

Fig.7 CSI cross-sectional BSE image after thermal exposure for different time at 1000 ^oC
(a) 100 h, (b) 200 h, (c) 500 h, (d) 1000 h, (e) 2000 h, (f) 4500 h

Fig.8 Original morphology (a), phase map (b), IPF image (c) and KAM image (d) of the cross-section below CSI after thermal exposure for 100 h at 1000 ^oC

Fig.9 Original morphology (a), phase map (b), IPF image (c) and KAM image (d) of the cross-section below CSI after thermal exposure for 4500 h at 1000 ^oC

Fig.10 Evolution of thickness of IDZ + SRZ with thermal exposure temperature and time

Fig.11 Schematic diagram of force decomposition in the direction of <001>

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