Corrosion Resistance of Ti3Al/BN Abradable Seal Coating

doi:10.1007/s40195-014-0133-4

Abstract

Abstract:

Ti-Al mixed powder (Ti:Al=3:1 in atomic ratio) and Ti₃Al intermetallic alloy powder mechanically clad hexagonal BN to fabricate TiAl/BN and Ti₃Al/BN composite powders. The corresponding porous abradable seal coatings (named as TAC-1 and TAC-2, respectively) were deposited using vacuum plasma spray (VPS) technology, and their corrosion behavior was studied via salt spray corrosion and electrochemical tests. Phase compositions and microstructures of these coatings before and after corrosion were characterized by X-ray diffraction (XRD) and scanning electron microscopy (SEM) facilitated with energy dispersive X-ray spectrometer (EDS). The results showed that spontaneous passivation of TAC-1 and TAC-2 granted the coatings excellent corrosion resistance than that of commercial Al/BN coating. Additionally, TAC-2 exhibited higher corrosion potential (E _corr) and breakdown potential (E _bp) but a lower corrosion current density (i _corr) than TAC-1. A small quantity of the corrosion product (Al(OH)₃ and AlO) could be detected on the surface of TAC-1, while no corrosion product appeared in TAC-2. The non-uniform elements distribution in the metal matrix of TAC-1 resulted in localized corrosion and relatively poor corrosion resistance compared to TAC-2.

Key words: Coating, Galvanic corrosion, Thermal spraying, Titanium aluminide

Zhang Feng, Lan Hao, Huang Chuanbing, Zhou Yang, Du Lingzhong, Zhang Weigang. Corrosion Resistance of Ti₃Al/BN Abradable Seal Coating[J]. Acta Metallurgica Sinica (English Letters), 2014, 27(6): 1114-1121.

Figures/Tables 17

Table 1 Vacuum plasma spray process parameters

Spray parameters	Value
Arc current	550-650 A
Primary plasma gas Ar	45-55 L/min
Secondary plasma gas H₂	12-15 L/min
Carrier gas Ar	2.0-2.5 L/min
Pressure of spraying atmosphere	12.5-15.0 kPa
Spray distance	150 mm

Fig. 1 Schematic diagram of the tested specimen

Fig. 2 Cross-section SEM images of the composite powders: a TiAl/BN; b Ti3Al/BN

Fig. 3 XRD patterns of the powders a and as-sprayed coatings b

Fig. 4 Cross-sectional micrographs of TAC-1 a, b TAC-2 coatings

Fig. 5 Free surface of the as-sprayed coatings after 960 h salt spray tests: a Al/BN coating; b TAC-1; c TAC-2

Fig. 6 Surface morphology of the TAC-1 after 960 h salt spray tests a, EDS result of the marked site in Fig. 6a b

Fig. 7 XRD pattern of the surface corrosion product of the TAC-1

Fig. 8 SEM image and the EDS results of the TAC-2 after 960 h salt spray corrosion test

Fig. 9 Open circuit potentials (E OCP) of the as-sprayed coatings

Fig. 10 Potentiodynamic polarization curves of the as-sprayed coatings

Table 2 Corrosion resistance parameters of Al/BN coating, TAC-1, and TAC-2

Sample	E _OCP (V)	E _corr (V)	E _pp (V)	E _bp (V)	i _corr (μA/cm²)
Al/BN	-1.13	-1.10	-	-	20.2
TAC-1	-0.61	-0.91	-0.75	-0.15	10.5
TAC-2	-0.22	-0.67	-0.52	0.02	5.1

Fig. 11 SEM image and EDS results of TAC-1

Fig. 12 SEM image and EDS results of TAC-2

Table 3 Chemical compositions of the marked areas shown in Fig. 11 analyzed by EDS (in wt%)

Element	Site 1	Site 2	Site 3	Site 4
Ti	94.5 ± 0.3	79.6 ± 0.9	75.5 ± 0.4	71.2 ± 1.1
Al	5.5 ± 0.3	20.4 ± 0.9	24.5 ± 0.4	28.8 ± 1.1

Table 4 Chemical compositions of the marked areas shown in Fig. 12 analyzed by EDS (in wt%)

Element	Site 1	Site 2
Ti	83.3 ± 0.4	85.8 ± 0.3
Al	16.7 ± 0.4	14.2 ± 0.3

Fig. 13 Surface morphology of the TAC-1 after 120 h salt spray tests a, EDS results of the sites marked by 1 b, 2 c in Fig. 13a

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Corrosion Resistance of Ti₃Al/BN Abradable Seal Coating

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