Coating-by-design: design a high-temperature oxidation and corrosion resistant Zr-doped MCrAlY coating fabricated by magnetron sputtering
Here, we propose a rapid coating design and verification approach via magnetron sputtering, which is first applied to Zr-doped MCrAlY coatings. By utilising the compositional gradient of the as-deposited coatings, ten candidates with varying Zr contents were evaluated. Among them, the coating with 0...
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Elsevier
2025-06-01
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| Series: | Applied Surface Science Advances |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2666523925000741 |
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| author | Shen Tao Hui Peng Anqin Zhang Hongbo Guo |
| author_facet | Shen Tao Hui Peng Anqin Zhang Hongbo Guo |
| author_sort | Shen Tao |
| collection | DOAJ |
| description | Here, we propose a rapid coating design and verification approach via magnetron sputtering, which is first applied to Zr-doped MCrAlY coatings. By utilising the compositional gradient of the as-deposited coatings, ten candidates with varying Zr contents were evaluated. Among them, the coating with 0.15 wt.% Zr exhibited the best oxidation and corrosion resistance. Results show that moderate Zr doping promotes the θ-Al2O3 to α-Al2O3 transformation and delays the β to γ/γ′ phase transition, leading to the formation of a dense and smooth oxide scale. However, EBSD analysis reveals that increasing Zr content coarsens the grain size, and excessive Zr accelerates Al depletion and promotes spinel formation. During oxidation, a semicoherent γ/γ′ to α-Al2O3 interface is formed, whereas in corrosion-tested samples, the β-NiAl to α-Al2O3 interface becomes incoherent, weakening interfacial bonding. Nevertheless, Zr diffusion from the coating into the thermally grown oxide (TGO) forms Zr-rich bands, which significantly inhibit Al outward diffusion. Thermo-Calc simulations indicate that the volume fraction of β-NiAl at 1100 °C (low Al content β-NiAl) is much higher than at 900 °C (high Al content β-NiAl), and that Zr has little effect on the overall phase distribution. Coatings prepared via arc ion plating further confirm that Zr-doped coatings outperform Zr-free ones in cyclic oxidation and corrosion resistance. |
| format | Article |
| id | doaj-art-bc11008f60a244479cba3d4d93e2b618 |
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| language | English |
| publishDate | 2025-06-01 |
| publisher | Elsevier |
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| spelling | doaj-art-bc11008f60a244479cba3d4d93e2b6182025-08-20T02:30:56ZengElsevierApplied Surface Science Advances2666-52392025-06-012710076610.1016/j.apsadv.2025.100766Coating-by-design: design a high-temperature oxidation and corrosion resistant Zr-doped MCrAlY coating fabricated by magnetron sputteringShen Tao0Hui Peng1Anqin Zhang2Hongbo Guo3School of Materials Science and Engineering, Beihang University, Beijing 100191, PR ChinaSchool of Materials Science and Engineering, Beihang University, Beijing 100191, PR China; Key Laboratory of High-Temperature Structural Materials & Coatings Technology, Ministry of Industry and Information Technology, Beihang University, 37 Xueyuan Road, Beijing, 100191, PR China; Corresponding author.AECC Guiyang Engine Design Research Institute, Guiyang 550081, PR ChinaSchool of Materials Science and Engineering, Beihang University, Beijing 100191, PR China; Key Laboratory of High-Temperature Structural Materials & Coatings Technology, Ministry of Industry and Information Technology, Beihang University, 37 Xueyuan Road, Beijing, 100191, PR ChinaHere, we propose a rapid coating design and verification approach via magnetron sputtering, which is first applied to Zr-doped MCrAlY coatings. By utilising the compositional gradient of the as-deposited coatings, ten candidates with varying Zr contents were evaluated. Among them, the coating with 0.15 wt.% Zr exhibited the best oxidation and corrosion resistance. Results show that moderate Zr doping promotes the θ-Al2O3 to α-Al2O3 transformation and delays the β to γ/γ′ phase transition, leading to the formation of a dense and smooth oxide scale. However, EBSD analysis reveals that increasing Zr content coarsens the grain size, and excessive Zr accelerates Al depletion and promotes spinel formation. During oxidation, a semicoherent γ/γ′ to α-Al2O3 interface is formed, whereas in corrosion-tested samples, the β-NiAl to α-Al2O3 interface becomes incoherent, weakening interfacial bonding. Nevertheless, Zr diffusion from the coating into the thermally grown oxide (TGO) forms Zr-rich bands, which significantly inhibit Al outward diffusion. Thermo-Calc simulations indicate that the volume fraction of β-NiAl at 1100 °C (low Al content β-NiAl) is much higher than at 900 °C (high Al content β-NiAl), and that Zr has little effect on the overall phase distribution. Coatings prepared via arc ion plating further confirm that Zr-doped coatings outperform Zr-free ones in cyclic oxidation and corrosion resistance.http://www.sciencedirect.com/science/article/pii/S2666523925000741Coating designMagnetron sputteringDopingOxidationCorrosion |
| spellingShingle | Shen Tao Hui Peng Anqin Zhang Hongbo Guo Coating-by-design: design a high-temperature oxidation and corrosion resistant Zr-doped MCrAlY coating fabricated by magnetron sputtering Applied Surface Science Advances Coating design Magnetron sputtering Doping Oxidation Corrosion |
| title | Coating-by-design: design a high-temperature oxidation and corrosion resistant Zr-doped MCrAlY coating fabricated by magnetron sputtering |
| title_full | Coating-by-design: design a high-temperature oxidation and corrosion resistant Zr-doped MCrAlY coating fabricated by magnetron sputtering |
| title_fullStr | Coating-by-design: design a high-temperature oxidation and corrosion resistant Zr-doped MCrAlY coating fabricated by magnetron sputtering |
| title_full_unstemmed | Coating-by-design: design a high-temperature oxidation and corrosion resistant Zr-doped MCrAlY coating fabricated by magnetron sputtering |
| title_short | Coating-by-design: design a high-temperature oxidation and corrosion resistant Zr-doped MCrAlY coating fabricated by magnetron sputtering |
| title_sort | coating by design design a high temperature oxidation and corrosion resistant zr doped mcraly coating fabricated by magnetron sputtering |
| topic | Coating design Magnetron sputtering Doping Oxidation Corrosion |
| url | http://www.sciencedirect.com/science/article/pii/S2666523925000741 |
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