Oxidation behavior of HVOF sprayed Ni–5Al coatings deposited on Ni- and Fe-based superalloys under cyclic condition

Ni–5Al coating was obtained on three superalloy substrates viz. Superni 76, Superni 750 and Superfer 800 using high velocity oxy-fuel (HVOF) spray process. Oxidation studies were carried out on both bare and coated superalloy substrates in air at 900 °C for 100 cycles. The weight change was measured at the end of each cycle and observed that the weight gain was high in Superni 750 alloy when compared to Superni 76 and Superfer 800. A nearly parabolic oxidation behavior was observed for Ni–5Al coated Superni 750 and Superfer 800 alloys but a Ni–5Al coated Superni 76 substrate showed a slight deviation. The scale was analysed using X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDAX) and electron probe microanalysis (EPMA). The coating increased the oxidation resistance for all the alloy substrates at 900 °C. Among the three-coated superalloys, Superfer 800 substrate has shown the best resistance to oxidation. The protective nature of the Ni–5Al coated superalloys was due to the formation of protective oxide scales such as NiO, Al2O3 and Cr2O3.