High temperature performance and interface evolution of a NiCoCrAlY coating with Pt modification and Re-based diffusion barrier

The cyclic and early isothermal oxidation behaviors at 1050 °C of the NiCoCrAlY, Pt-modified NiCoCrAlY and Pt-modified NiCoCrAlY with Re-based diffusion barrier (DB) have been evaluated. The atomic immigration and electron location function (ELF) at the Ni-Re interface were simulated by density function theory (DFT) calculations. After isothermal oxidation for 1 h, island NiCoCrAlY particles with extremely poor Al were observed in the oxide scale of normal NiCoCrAlY coating, and then the oxide scale transformed into a double-layer structure after oxidation for 20 h. The initial “island-oxide” scale model was proposed to illustrate the oxidation mechanisms for normal NiCoCrAlY coating. The oxide scale of Pt-modified NiCoCrAlY coating was single-layer Al2O3 with rapid coverage at the surface, because the modification of Pt changed the initial oxidation mechanism by promoting the uphill diffusion of Al. The Re-based DB reduced the thickness of the secondary reaction zone (SRZ) by inhibiting the element interdiffusion between the NiCoCrAlY coating and the substrate, thus the Pt-modified NiCoCrAlY with Re-based DB exhibited the lowest interdiffusion extent. Interestingly, the thermal stability of Re-based DB in NiCoCrAlY coating system was poorer than that in NiCrAlY system. The DFT simulation shows that the incorporation of Co made the energy difference more negative, which confirmed that Co promoted the diffusion of Re in the NiCoCrAlY coating, thus accelerating the degradation of Re-based DB.