Search Results (106)

The slurry aluminizing process is widely employed to enhance the oxidation and corrosion resistance of nickel-based superalloys used in high-temperature environments such as gas turbines and aerospace engines. This study investigates the effects of the concentration of Al vapors in the reactor chamber and the initial slurry layer thickness on the microstructure, chemical composition, and phase composition of aluminide coatings. Coatings were manufactured on Ni-based superalloy substrates using CrAl powders as an aluminum source and chloride- and fluoride-based activator salts. The effect of the initial thickness of the slurry layer was studied by varying the amount of deposited slurry in terms of mg_slurry/cm²_sample (with constant mg_slurry/cm³_chamber). The microstructure and phase composition of the produced aluminide coatings were evaluated by SEM, EDS, and XRD analysis. Slurry thickness can affect concentration gradients during diffusion, and the best results were obtained with an initial slurry amount of 100 mg_slurry/cm²_sample. The effect of the Al vapor phase in the reaction chamber was then investigated by varying the mg_slurry/cm³_chamber ratio while keeping the slurry layer thickness constant at 100 mg_slurry/cm²_sample. This parameter influences the amount of Al at the substrate surface before the onset of solid-state diffusion, and the best results were obtained for a 6.50 mg_slurry/cm³_chamber ratio with the formation of 80 µm coatings (excluding the interdiffusion zone) with a β-NiAl phase throughout the thickness. To validate process flexibility, the same parameters were successfully applied to produce platinum-modified aluminides with a bi-phasic ζ-PtAl2 and β-(Ni,Pt)Al microstructure. Full article

Aluminide coatings on nickel-based superalloys were synthesized via a high-temperature “clean” low-activity vapor-phase process. This process is environmentally friendly and meets manufacturers’ environmental protection requirements. Hence, it fulfils the Industry 4.0 requirements, where the reduction of environmental impact in the industrial sector is a key issue. Surface morphology, cross-section microstructure, and phase composition of the coatings were studied and compared by using an optical microscope and a scanning electron microscope (SEM) equipped with an energy dispersive spectroscope (EDS) and X-ray diffraction (XRD). Bare and coated superalloys’ lifetime was evaluated and compared via air exposure at 1100 °C. High-temperature low-activity aluminizing of the IN713, IN625, and CMSX4 superalloys enabled the obtainment of the desirable β-NiAl phase. The highest nickel content in the chemical composition of the IN713 superalloy among the investigated superalloys resulted in the highest aluminide coatings’ thickness. Moreover, the higher refractory elements concentration in the IN625 and CMSX4 superalloys than that in the IN713 superalloy may contribute to a thinner aluminide coatings’ thickness. Refractory elements diffused to the surface of the superalloy and formed carbides or intermetallic phases, which impeded outward nickel diffusion from the substrate to the surface and thereby inhibited coating growth. The obtained coatings fulfilled the requirements of ASTM B 875. Despite the fact that the coating formed on IN713 was thicker than that formed on IN625, the lifetime of both coated superalloys was comparable. Oxidation resistance of the aluminide coatings formed on the IN713 and IN625 superalloys makes them the favored choice for gas turbine applications. Full article

Nano-titanium dioxide ceramic coatings exhibit excellent wear resistance, corrosion resistance, and self-cleaning properties, showing great potential as multifunctional protective materials. This study proposes a synergistic reinforcement strategy by encapsulating micron-sized Al₂O₃ particles with nano-TiO₂. A core-shell structured nanocomposite coating composed of 65 wt% nano-TiO₂ encapsulating 30 wt% micron-Al₂O₃ was precisely designed and fabricated via a slurry dip-coating method on Q235 steel substrates. The microstructure and surface morphology of the coatings were characterized using scanning electron microscopy (SEM) and X-ray diffraction (XRD). Comprehensive performance evaluations including densification, adhesion strength, wear resistance, and thermal shock resistance were conducted. Optimal coating properties were achieved under the conditions of a binder-to-solvent ratio of 1:15 (g/mL), a heating rate of 2 °C/min, and a sintering temperature of 400 °C. XRD analysis confirmed the formation of multiple crystalline phases during the 400 °C curing process, including titanium pyrophosphate (TiP₂O₇), aluminum phosphate (AlPO₄), copper aluminate (Cu(AlO₂)₂), and a unique titanium phosphate phase (Ti₃(PO₄)₄) exclusive to the 2 °C/min heating rate. Adhesion strength tests revealed that the coating sintered at 2 °C/min exhibited superior interfacial bonding strength and outstanding performance in wear resistance, hardness, and thermal shock resistance. The incorporation of nano-TiO₂ into the 30 wt% Al₂O₃ matrix significantly enhanced the mechanical properties of the composite coating. Mechanistic studies indicated that the bonding between the nanocomposite coating and the metal substrate is primarily achieved through mechanical interlocking, forming a robust physical interface. These findings provide theoretical guidance for optimizing the fabrication process of metal-based ceramic coatings and expanding their engineering applications in various industries. Full article

Hot stamping is a promising method to manufacture ultra-high-strength automotive steel components with high dimension accuracy. In this work, two actual industrial production flows (with and without Al-Si hot dipping) were investigated to reveal their microstructural evolution and hydrogen content at different production steps. Meanwhile, the variations in composition and phase structures of the Al-Si coating layer were studied in terms of energy-dispersive spectrometry and electron backscattering diffraction techniques. The results showed that the microstructure at the steel substrate changed from the pancake-shaped pearlite and ferrite, degenerated pearlite and annealed ferrite, lath martensite, and then tempered martensite with the progress of the production steps, which was not affected by the Al-Si hot dipping. The final coating layer exhibited a multi-sublayer structure with the alternative distribution of FeAl and Fe₂Al₅, which contained many microcracks on the brittle phase Fe₂Al₅. The Al-Si-coated specimens always had higher hydrogen content than the bare steel specimens because of the hydrogen generation at the hot stamping stage and hydrogen absorption during the hot-dip aluminizing stage. Full article

This study systematically explores and expands upon the research questions, revealing the scientific principles and engineering value of chromium–aluminum (Cr-Al) co-diffusion coatings in enhancing high-temperature friction performance. This study addresses the critical need for wear resistance in GH5188 cobalt-based alloy stator bushings operating in high-temperature environments. The high-temperature wear resistance mechanism of aluminized coatings modified with Cr elements on the GH5188 alloy, based on thermal diffusion technology, was investigated. The experimental results indicate that the high-temperature wear resistance of the samples was directly related to the type and content of oxides in the wear scars and debris. After friction at 700 °C, the aluminized coating on the GH5188 alloy showed the lowest oxide content in the wear scars, primarily composed of CoAl₂O₄. The oxides in the wear scars of the GH5188 alloy and Al-Cr co-aluminized coatings were mainly CoCr₂O₄ and Cr₂O₃, with the Al-Cr co-aluminized coating showing the highest amount of wear debris. The Cr-rich oxide debris not only has high thermodynamic stability but also exhibits relatively low high-temperature growth stress, making it difficult to spall. Additionally, the higher diffusion coefficient of Cr³⁺ accelerates the reoxidation of wear debris pits, resulting in excellent high-temperature wear resistance. The wear rate of the Al-Cr co-aluminized coating was reduced by 30% compared with the GH5188 substrate and by 69% compared with the aluminized coating. In summary, the key findings are not only applicable to cobalt-based alloys but can also be extended to a broader range of material systems and engineering applications. This provides new perspectives and methodologies for the design of high-temperature coatings, the development of materials for extreme conditions, and interdisciplinary applications. Full article

Microstructure evolution and cracking behavior of a four-layer thermal barrier coating (TBC) with double YSZ layers during thermal cycle tests were studied in the current work. The temperature range of the thermal cycle test ranged from room temperature to 1100 °C under atmospheric conditions. The TBC consisted of tetragonal t′ and t phases as well as monoclinic yttrium oxide. After 500 thermal cycles, the m-ZrO₂ phase was formed through the phase transformation from t′-ZrO₂ to m-ZrO₂ and c-ZrO₂. A large number of bulk thermally grown oxides (TGO), including chromium, spinel, and yttrium aluminates, were formed around pores in the transition layer (TL). Furthermore, the thickness of the TGO layer increased with a relatively low increase rate during the test (where k_p was about 0.17 μm²/h). This may be attributed to the formation of bulk TGO around pores within the TL, which could consume some of the oxygen. The results show that large horizontal cracks are likely to form at the TSL/TIL and TIL/TL interfaces, while vertical cracks tend to occur near the surface of the TSL, and the propagation rate is relatively low. The propagation of horizontal cracks is the primary cause of failure in this four-layer structure. After the thermal cycle test, the porosity of TSL decreased significantly, from 7.17% to 0.76%. The results in this study may help optimize the design and preparation of TBCs with double YSZ layers. Full article

Aircraft engine turbine blades are covered with protective coatings. These coatings should have the best thermophysical convergence with the blade’s parent material. The aim is to create heat-resistant covering for aircraft engine turbine blades made of nickel superalloy. The results of tests on coatings are presented; the inner layer is an adhesive layer of the MeCrAlY type, applied to the blade by means of supersonic thermal spraying, and the outer layer is diffusion-aluminized in the first case using the Vapor Phase Aluminizing method, and in the second using the suspension method. The inner layer of the coating protects the blade material against high-temperature corrosion, and the outer layer against high-temperature fuel combustion product stream. The protective coatings applied to aircraft engine turbine blades were subjected to an engine test in test bench conditions and then to material tests. A protective coating with an internal layer of MeCrAlY type applied to the blade by supersonic spraying and an external layer aluminized by the Vapor Phase Aluminizing method protects the nickel superalloy against high-temperature diffusion changes, protects it against oxidation and provides it thermal insulation. Full article

In this work, the oxidation behavior of an aluminide coating at 900, 1000, and 1100 °C was investigated. The aluminide coating was prepared on a cobalt-based superalloy using a vapor phase aluminizing process, which is composed of a β-(Co,Ni)Al phase outer layer and a Cr-rich phase diffusion layer. The experimental results showed that the oxidation of the coating at 900–1100 °C all obey the parabolic law. The oxidation rate constants of the coating were between 2.19 × 10⁻⁷ and 47.56 × 10⁻⁷ mg²·cm⁻⁴·s⁻¹. The coating produced metastable θ-Al₂O₃ at 900 °C and stable α-Al₂O₃ at 1000 and 1100 °C. As the oxidation temperature increases, the formation of Al₂O₃ is promoted, consuming large amount of Al in the coating, resulting in the transformation from β-(Co,Ni)Al phase to α-(Co,Ni,Cr) phase. And the decrease in the β phase in the coating led to the dissolution of the diffusion layer. Full article

In order to enhance the resistance of superalloys to high-temperature molten chloride salt corrosion, Fe-Al coatings were prepared on 310S and 347H stainless-steel surfaces via pack aluminizing. Then, the coatings were annealed at different temperatures to explore the influence of temperature on their phase constitution, microstructure, microhardness, and corrosion resistance. The results showed that the annealing temperature had a considerable effect on the corrosion resistance of the Fe-Al coatings, which was related to the change in the phase composition of the coatings that occurred due to the annealing treatment. The growth rate of the coating on 347H steel was higher than that on 310S steel, and their thicknesses from aluminizing at 800 °C for 20 h were 209.6 and 153.5 µm, respectively. When annealing at 900 °C for 30 h, the phase composition of the coatings was completely transformed into (Fe, Cr, Ni) Al. The corrosion loss rate of the annealed coating was clearly reduced, the loss rate of the 310 coating was 6.0 and −0.25 mg/cm² before and after annealing at 900 °C and that of the 347 coating was 4.89 and −0.7 mg/cm² before and after annealing at 750 °C, respectively. The two coatings showed good corrosion resistance to molten chloride salts, as demonstrated by the oxide scale (Al₂O₃) that formed on the surface, which had a thickness of about 30~40 µm. Full article

In this paper, the results of a study of the structure and phase composition of the hot-dip aluminizing coatings formed on the commercially pure titanium surface in AW-6063 aluminum alloy melt after heat treatment at 700 and 850 °C are presented. It is shown that as a result of aluminizing on the titanium surface, a homogeneous coating 30–40 µm thick without defects is formed. The hot-dip aluminizing coating consists of aluminum and the intermetallic compound TiAl₃, located at the boundary with the substrate. Heat treatment results in the formation of a heterogeneous coating structure: its outer layer has a frame-type structure consisting of TiAl₃ particles surrounded by an Al₂O₃ + TiO₂ grid, and the inner continuous layer adjacent to the titanium consists of TiAl₂, TiAl, and Ti₃Al intermetallic layers. Increasing in the heat treatment temperature and/or holding time results in an increase in the thickness of both the outer and boundary layers of the coating. A mechanism for the formation of the coating structure via heat treatment is proposed. The scratch test method was used to evaluate the cohesive and adhesive strength of the coatings, and their scratch hardness was determined, which averaged 200 MPa. It was shown that the coating structure formed during heat treatment at 850 °C ensures higher resistance to cohesive failure. Full article

High-temperature corrosion within waste incineration boilers leads to the thinning of their four-tube heating surfaces and frequent tube ruptures, posing a formidable challenge to the development of the waste-to-energy sector. This predicament critically constrains the advancement of China’s waste management and environmental protection sectors. This study focuses on elucidating high-temperature corrosion mechanisms and exploring coating protection methodologies relevant to waste boilers. For corrosion mechanisms, the study comprehensively reviews various factors such as the characteristics of high-temperature chlorine-induced corrosion, gaseous- and molten-chloride-induced corrosion, and sulfidation and multiphase-coupled corrosion; the influence of wall temperature on corrosion; and temperature effects on corrosion. Regarding coating protection technologies, this study traces the historical progression of various coating techniques, providing an overview of methods such as supersonic flame spraying, Inconel 625 surfacing, laser cladding, induction melting, thermosetting-reaction nanoceramic coating, and aluminizing. Special emphasis is placed on the mechanisms and principles of the widely adopted surfacing and induction melting techniques. Overall, the study ventures into the prevailing challenges and envisions the future trajectories of high-temperature anticorrosion mechanisms and coating protection technologies for China’s waste boiler sector. Full article

Inorganic cool pigments are widely used as cooling agents in residential coatings due to their ability to achieve near-infrared reflectance. These coatings can be designed to exhibit a variety of colors independent of their reflectivity and absorption properties. Recent studies have highlighted the development of novel near-infrared (NIR) blue pigments, with an increasing emphasis on environmentally sustainable options that demonstrate high NIR reflectivity. This trend highlights the importance of creating novel and eco-friendly NIR reflective blue pigments. This study presents the synthesis of cobalt aluminates with varying concentrations of coloring ions (Co²⁺), achieved through the recycling of aluminum can seals via chemical precipitation. The formation of the spinel phase was confirmed through X-ray diffraction (XRD), and a colorimetric analysis was performed in the CIEL*a*b* color space. The synthesized pigments exhibited high near-infrared solar reflectance, with R% values ranging from 34 to 54%, indicating their potential as energy-efficient color pigments for use in coatings. Full article

High levels of unsaturated fatty acids in Brazil nuts compromise their sensory quality through lipid oxidation. To mitigate this reaction, it is crucial to package nuts under a vacuum and in aluminate packaging. An alternative method is the application of an edible coating with antioxidant properties. This study aimed to develop an edible coating composed of carboxymethylcellulose and sorbitol, physically reinforced with nanocellulose, and chemically fortified with tocopherol. The edible coating was characterized based on its physical properties, mechanical strength, biodegradability, optical light transmission properties, color parameters, and water vapor permeability. Formulations CC5 (Carboxymethyl cellulose (CMC) + sorbitol + 5% nanocellulose) and CCT5 (CMC + sorbitol + tocopherol + soy lecithin + 5% nanocellulose) showed enhanced mechanical strength. The combination of nanocellulose with tocopherol in formulations CCT3 (CMC + sorbitol + tocopherol + soy lecithin + 3% nanocellulose) and CCT5 developed superior barriers to visible and ultraviolet light, a desired characteristic for coatings intended to increase the shelf life of Brazil nuts. The nuts coated with CC5 and CCT3 showed the lowest PV values at the end of the accelerated oxidation test conducted at 60 °C. Full article

The fabrication of a single-phase (Ni,Pt)Al coating, doped with zirconium, was achieved via a method that included the simultaneous electroplating of a Pt-Zr layer, followed by a process of gas-phase aluminizing. The Zr-doped (Ni,Pt)Al coating was then subjected to an evaluation of its isothermal oxidation resistance at a temperature of 1150 °C in static air compared with a conventional (Ni,Pt)Al coating. The findings indicated that the incorporation of zirconium into the (Ni,Pt)Al coating led to a marked escalation in the rate of oxidation and a worse-scale spallation resistance, which was totally opposite to the results obtained at 1100 °C. The harmful effect of Zr on the oxidation resistance of the coating is discussed in this paper. Full article

This paper reviews the research progress and development of aluminate long afterglow luminescent materials in the field of road marking, especially the study of rare earth ion-activated strontium aluminate (SrAl₂O₄: Eu²⁺, Dy³⁺)-based long afterglow powders. This article begins by describing the importance of road markings and the need to improve their visibility and durability at night and in adverse weather conditions. Subsequently, the current passive and active methods for improving the visibility of marking materials are discussed in detail, focusing on the advantages of aluminate long afterglow materials and challenges related to their hydrolysis and thermal stability. Through the application of organic–inorganic composite coating technology, the water resistance and thermal stability of the materials can be improved, thus enhancing the performance of road markings. This article also summarizes the current research status of different types of long afterglow road marking coatings. It analyzes the luminescence mechanism of aluminate long afterglow materials. Additionally, this article discusses future research directions and application prospects. The aim is to provide technical references and support for the wide application of long afterglow self-luminous road marking coatings. Full article