High-temperature oxidation of an aluminized NiCr alloy formed by a magnetron-sputtered Al diffusion coating

Aluminium diffusion coatings were obtained on Ni-20Cr substrate by sputtering an aluminium film, followed by a two stage diffusion treatment in an argon inert gas atmosphere (first stage at 600°C, second at 900 or 1100°C). Aluminides obtained at 900°C and 1100°C are close to those obtained by pack cementation process with high aluminium activity. These diffusion coatings are able to develop alumina scales during isothermal oxidation at high temperatures, whereas the untreated substrate had a chromia-forming behaviour. The weight gain recorded at 1100°C on coated sample is then smaller than the one of uncoated NiCr at 950°C. Presence of chromium was detected in the diffusion coating and Cr-rich precipitates were observed at the diffusion coating/substrate interface. After oxidation at 900°C and 1100°C, only α-AlO was revealed by XRD. An intermediate scale with a "whiskered" morphology could however be observed after 48 hr oxidation at 900°C. After 100 hr of oxidation at 1100°C, the Ni Al diffusion phases were no longer detectable and the upper part of the oxide scale spalled away during cooling. Large cavities appeared at the initial location of the diffusion coating/substrate interface. © 2005 Springer Science+Business Media, Inc.