Microstructure characterisation of un-melted particles in a plasma sprayed CoNiCrAlY coating
- Department of Mechanical, Materials and Manufacturing Engineering, Faculty of Science and Engineering, University of Nottingham Ningbo China, Ningbo 315100 (China)
Highlights: • The microstructure of the CoNiCrAlY powder particles was studied. • The un-melted particles in the VPS CoNiCrAlY coating were investigated. • A semi-continuous β-phase layer was found around the un-melted particles. • Micro-cracks were formed along the un-melted particles under compression. - Abstract: Un-melted particles in thermally sprayed coatings are usually classified as impurity elements. Such impurities have a strong influence on the coating behaviour due to their different microstructural characteristics. In this work, the microstructural and mechanical characteristics of un-melted particles in a vacuum plasma sprayed CoNiCrAlY coating have been investigated. Microstructural analysis revealed the dendritic structure of the as-received powder and a spherical core inside the powder particle. The as-deposited coating comprised a dual phase structure of γ-Ni and β-NiAl, with coarse grains ranging 1–2 μm and fine grains ranging 500 nm or even less. Un-melted particles were found to exist in the coating after plasma spraying. The grain structure in the un-melted particles has not been fully developed, as characterised via electron backscattered diffraction (EBSD). It is shown that the spherical core in the initial powder was retained as un-melted particles due to insufficient melting during plasma spraying. In addition, a semi-continuous β-phase layer was found at the un-melted particle boundaries. Due to the inherently brittle nature of the β-phase layer and poor bonding at the particle boundaries, cracking along the un-melted particle boundaries occurred under compression.
- OSTI ID:
- 22804874
- Journal Information:
- Materials Characterization, Vol. 136; Other Information: Copyright (c) 2017 Elsevier Science B.V., Amsterdam, The Netherlands, All rights reserved.; Country of input: International Atomic Energy Agency (IAEA); ISSN 1044-5803
- Country of Publication:
- United States
- Language:
- English
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