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NiCrAlY coatings were prepared by the newly-developed detonation gun spray process. The oxide scale formation and evolution on these coatings during isothermal oxidation in air at 1100 degrees C were investigated. It was found that semi-molten particles, particle debris and pores, are present in the surface layer of the as-sprayed coating. During 100 h oxidation, the particle debris and some semi-molten particles gradually change into oxide mixture consisting of spinel, chromia and nickel oxides. However, after removal of the surface layer of the coating by a grinding treatment, a dense and single-layer alpha-Al2O3 scale forms on the surface of the coating during the oxidation. The mechanisms governing the oxide scale formation and evolution are discussed in terms of atomic diffusion and thermodynamic stability. In addition, thermogravimetric analysis showed that the oxidation rate of the ground NiCrAlY coating at 1100 degrees C is much lower than that of the as-sprayed one. The residual stress in thermally grown oxide scales was investigated using photo-stimulated luminescence spectroscopy.

The Oxide Scale Formation and Evolution on Detonation Gun Sprayed NiCrAlY Coatings during Isothermal Oxidation