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Oxidation behavior and characterization of ZrO2/Cr94Al6 composite coated Zr-Sn alloy in 1000–1200 °C steam.

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Title: Oxidation behavior and characterization of ZrO2/Cr94Al6 composite coated Zr-Sn alloy in 1000–1200 °C steam.
Authors: Zhou, Qian1 (AUTHOR), Chen, Hu1 (AUTHOR), Li, Xin1 (AUTHOR), Jin, Xiaoyue2 (AUTHOR), Du, Jiancheng1 (AUTHOR), Xu, Chi1,2 (AUTHOR) xuchi@bnu.edu.cn, Liao, Bin1 (AUTHOR), Xue, Luwei3,4 (AUTHOR), Wang, Rongshan3,4 (AUTHOR), Zhao, Wanxiang3,4 (AUTHOR), Xue, Wenbin1,2 (AUTHOR)
Source: Ceramics International. Sep2025:Part B, Vol. 51 Issue 21, p34831-34845. 15p.
Subject Terms: *ELECTROLYTIC oxidation, *VACUUM arcs, *ALUMINUM oxide, *COMPOSITE coating, *VACUUM deposition
Abstract: A ZrO 2 /Cr 94 Al 6 composite coating, denoted as the PEO/Cr 94 Al 6 , was successfully fabricated on Zr-Sn alloy using a combination of plasma electrolytic oxidation (PEO) and filtered cathodic vacuum arc deposition (FCVAD) technologies. The PEO process served to form an insulating ZrO 2 ceramic interlayer, which not only acted as a physical barrier to impede the inter-diffusion between the Cr-based coating and the Zr substrate, but also inhibited the CrAl/Zr galvanic corrosion. The oxidation behavior of this ZrO 2 /Cr 94 Al 6 -coated alloy in 1000–1200 °C steam was comprehensively evaluated. It was found that the mass gains of PEO/Cr 94 Al 6 -coated samples were merely 16.7 %, 22.5 % and 27.8 % of bare Zr-Sn alloy after 3600 s exposure in 1000 °C, 1100 °C and 1200 °C steam, respectively. The oxidative activation energy of bare and PEO/Cr 94 Al 6 -coated Zr-Sn alloys is 220.41 kJ/mol and 404.78 kJ/mol, respectively. Their excellent oxidation resistance was ascribed to the formation of outer Cr 2 O 3 layer and the internal Al 2 O 3 barrier layer above the residual CrAl layer. The thin Al 2 O 3 barrier layer, in particular, effectively suppressed the inward diffusion of oxygen and played one key role in enhancing the oxidation resistance of composite coating. At 1000 °C and 1100 °C, a Cr 2 Zr inter-diffusion layer was formed between the CrAl layer and the Zr - Sn alloy substrate. However, at 1200 °C, a complex three-layer diffusion structure emerged, consisting of different Zr-Cr-O phases. This structure evolution was closely related to the diffusion of Cr, Al, and O elements, as well as the phase transformation of the PEO-derived ZrO 2 layer to Zr 3 O and α-Zr(O). [ABSTRACT FROM AUTHOR]
Database: Academic Search Index
Description
Abstract:A ZrO 2 /Cr 94 Al 6 composite coating, denoted as the PEO/Cr 94 Al 6 , was successfully fabricated on Zr-Sn alloy using a combination of plasma electrolytic oxidation (PEO) and filtered cathodic vacuum arc deposition (FCVAD) technologies. The PEO process served to form an insulating ZrO 2 ceramic interlayer, which not only acted as a physical barrier to impede the inter-diffusion between the Cr-based coating and the Zr substrate, but also inhibited the CrAl/Zr galvanic corrosion. The oxidation behavior of this ZrO 2 /Cr 94 Al 6 -coated alloy in 1000–1200 °C steam was comprehensively evaluated. It was found that the mass gains of PEO/Cr 94 Al 6 -coated samples were merely 16.7 %, 22.5 % and 27.8 % of bare Zr-Sn alloy after 3600 s exposure in 1000 °C, 1100 °C and 1200 °C steam, respectively. The oxidative activation energy of bare and PEO/Cr 94 Al 6 -coated Zr-Sn alloys is 220.41 kJ/mol and 404.78 kJ/mol, respectively. Their excellent oxidation resistance was ascribed to the formation of outer Cr 2 O 3 layer and the internal Al 2 O 3 barrier layer above the residual CrAl layer. The thin Al 2 O 3 barrier layer, in particular, effectively suppressed the inward diffusion of oxygen and played one key role in enhancing the oxidation resistance of composite coating. At 1000 °C and 1100 °C, a Cr 2 Zr inter-diffusion layer was formed between the CrAl layer and the Zr - Sn alloy substrate. However, at 1200 °C, a complex three-layer diffusion structure emerged, consisting of different Zr-Cr-O phases. This structure evolution was closely related to the diffusion of Cr, Al, and O elements, as well as the phase transformation of the PEO-derived ZrO 2 layer to Zr 3 O and α-Zr(O). [ABSTRACT FROM AUTHOR]
ISSN:02728842
DOI:10.1016/j.ceramint.2025.05.205