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<p>The N5 nickel-based single-crystal superalloy is critical for aero-engine blades, yet its high-temperature interdiffusion with NiCrAlY coatings promotes the formation of detrimental topologically close-packed (TCP) phases, which degrade the coating performance. To investigate this issue, a coupled finite-element and phase-field model was developed to simulate the interdiffusion process at 1050&#xa0;°C for 300&#xa0;h, comparing systems with and without a NiRe diffusion barrier. The results reveal a stark contrast: Without the barrier, severe interdiffusion leads to a 78.44-μm-thick TCP layer and interfacial stress up to 8&#xa0;kPa. In contrast, the NiRe barrier reduces the Al/Cr diffusion fluxes by two orders of magnitude, cuts the TCP thickness by 68% to 24.6&#xa0;μm, lowers the peak stress by 31% to 5.5&#xa0;kPa, and better retains Al within the coating. These findings confirm that the NiRe layer acts as an effective physicochemical barrier, simultaneously suppressing interdiffusion and TCP phase precipitation.</p>

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Simulation and experimental study on the inhibition effect of NiRe diffusion barrier in superalloy coating systems

  • 期刊论文

  • 发表日期：

    2026年3月9日

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  • Zhiyu Gao,
  • Xin Liu,
  • Zi Liang,
  • He Liu

摘要

The N5 nickel-based single-crystal superalloy is critical for aero-engine blades, yet its high-temperature interdiffusion with NiCrAlY coatings promotes the formation of detrimental topologically close-packed (TCP) phases, which degrade the coating performance. To investigate this issue, a coupled finite-element and phase-field model was developed to simulate the interdiffusion process at 1050 °C for 300 h, comparing systems with and without a NiRe diffusion barrier. The results reveal a stark contrast: Without the barrier, severe interdiffusion leads to a 78.44-μm-thick TCP layer and interfacial stress up to 8 kPa. In contrast, the NiRe barrier reduces the Al/Cr diffusion fluxes by two orders of magnitude, cuts the TCP thickness by 68% to 24.6 μm, lowers the peak stress by 31% to 5.5 kPa, and better retains Al within the coating. These findings confirm that the NiRe layer acts as an effective physicochemical barrier, simultaneously suppressing interdiffusion and TCP phase precipitation.