Synthesis and characterization of superalloy coatings by cathodic arc evaporation

- Superalloy substrate-identical targets were fabricated and utilized in non-reactive and reactive cathodic arc deposition
- The chemical composition and structure of the targets were also found in the synthesized superalloy coating
- In-situ processing is demonstrated for the whole bond coat
- Epitaxial growth was achieved in the interface between superalloy coating and superalloy substrate

Superalloy targets were produced from Ni-(Al-C-Co-Cr-Mo-Ta-Ti-W) powders by spark plasma sintering technology. The crystalline structure of the as-produced targets was investigated by XRD analysis and compared with the evolution of phases resulting from the operation of the cathodic arc at the target (cathode) surface. Coatings were synthesized at superalloy substrates utilizing these superalloy targets in non-reactive and reactive evaporation processes. Synthesized coatings and target surfaces were compared with respect to chemical composition and crystal structure. The interface between coating and superalloy substrates was investigated by TEM. As an example, a complete layer stack was synthesized by cathodic arc evaporation starting from the superalloy substrate - superalloy coating interface to a fully oxidized superalloy coating showing epitaxial growth in the interface to the superalloy substrate.