Initial Aluminizing Steps of Pure Nickel from Al Micro-Particles

TLDR: In this article, the effects of moderate temperatures (550-700°C), dwelling times and Al particle size on the final characteristics of the coatings were investigated. But the results showed that the increase of dwelling time did not provide any significant thickness increase as the Al particles got practically emptied after 2h.

Abstract: Novel, unconventional type of high temperature coating systems can be elaborated by depositing Al micro-particles on nickel base substrates, using an appropriate binder, and converting them into a thermal barrier type coating by a two-step heat treatment under argon. Final result is a coating structure consisting of a quasi-foam top coat, constituted by spherical hollow alumina particles, surmounting a β-NiAl diffusion layer able to form during high-temperature oxidation a protective alumina scale. In this work, pure nickel was employed as a model material to evaluate the effects of moderate temperatures (550-700°C), dwelling times and Al particle size on the final characteristics of the coatings. Almost no diffusion occurred below 600°C. In contrast, a Ni2Al3 layer very quickly formed at 650 or 700°C. The rapidity of coating formation was attributed to the appearance of a liquid phase at the coating/substrate interface. The increase of dwelling time did not provide any significant thickness increase as the Al particles got practically emptied after 2h. In addition, the use of different micro-sized particles resulted in similar Al diffusion coatings under the investigated conditions.