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<p>To enhance the corrosion resistance of NiCoCrAlY coatings in high-temperature salt-containing environments, this study employed resonant acoustic mixing technology to coat NiCoCrAlY powder surfaces with 1.0 wt.% nano-sized CeO<sub>2</sub> particles of two diameters (20&#xa0;nm and 100&#xa0;nm), fabricating oxide dispersion-strengthened composite powders. Three types of free-standing coatings were subsequently prepared via high-velocity oxygen fuel (HVOF) spraying: unmodified NiCoCrAlY (NC) coating, NC-20Ce coating (incorporating 20 nmCeO<sub>2</sub>), and NC-100Ce coating (incorporating 100 nmCeO<sub>2</sub>). The hot corrosion behavior of the three coatings was systematically investigated in a mixed salt environment (75 wt.% Na<sub>2</sub>SO<sub>4</sub> + 25 wt.% NaCl) at 900°C for 100&#xa0;h. Characterizations and analyses were performed using scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), X-ray diffraction (XRD), and corrosion kinetics calculations. The results demonstrate that the composite coatings exhibit superior hot salt corrosion resistance compared with the traditional NC coating, with the 20 nmCeO<sub>2</sub>-modified coating showing the greatest improvement. Furthermore, thermodynamic calculations show that nano-CeO<sub>2</sub> can effectively trap sulfur by forming stable Ce<sub>2</sub>O<sub>2</sub>S compounds, providing theoretical support for the coatings' sulfidation resistance mechanism. The NiCoCrAlY coating modified with 1.0wt.% nano-CeO<sub>2</sub> holds promise as a candidate protective material for the high-temperature sections of gas turbines in the future.</p>

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Study on the Preparation of NiCoCrAlY Coatings with Structurally Controlled Nano-CeO2 and Their High-Temperature Thermal Corrosion Behavior

  • 期刊论文

  • 发表日期：

    2026年5月26日

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  • Fukang Yue,
  • Zhaoran Zheng,
  • Jianming Liu,
  • Huaixu Guo,
  • Xiaoliang Lu,
  • Yingjie Han,
  • Peixuan Ouyang,
  • Shuting Zhang

摘要

To enhance the corrosion resistance of NiCoCrAlY coatings in high-temperature salt-containing environments, this study employed resonant acoustic mixing technology to coat NiCoCrAlY powder surfaces with 1.0 wt.% nano-sized CeO2 particles of two diameters (20 nm and 100 nm), fabricating oxide dispersion-strengthened composite powders. Three types of free-standing coatings were subsequently prepared via high-velocity oxygen fuel (HVOF) spraying: unmodified NiCoCrAlY (NC) coating, NC-20Ce coating (incorporating 20 nmCeO2), and NC-100Ce coating (incorporating 100 nmCeO2). The hot corrosion behavior of the three coatings was systematically investigated in a mixed salt environment (75 wt.% Na2SO4 + 25 wt.% NaCl) at 900°C for 100 h. Characterizations and analyses were performed using scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), X-ray diffraction (XRD), and corrosion kinetics calculations. The results demonstrate that the composite coatings exhibit superior hot salt corrosion resistance compared with the traditional NC coating, with the 20 nmCeO2-modified coating showing the greatest improvement. Furthermore, thermodynamic calculations show that nano-CeO2 can effectively trap sulfur by forming stable Ce2O2S compounds, providing theoretical support for the coatings' sulfidation resistance mechanism. The NiCoCrAlY coating modified with 1.0wt.% nano-CeO2 holds promise as a candidate protective material for the high-temperature sections of gas turbines in the future.