MCrAlY (M = Ni, Co) coatings are commonly used to protect the underlying superalloy component in industrial gas turbines and aeroengines from oxidation attack. They also function as bond coats for thermal barrier coatings (TBC). The chemical life time of the coated component is mainly governed by the depletion of the β-phase in the bond coat as a result of simultaneously occurring surface oxidation and interdiffusion between the coating and the substrate. A new computational approach to model the microstructural evolution in MCrAlY (M = Ni, Co) coatings on Ni base superalloys was undertaken in the present study. Scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX) and wavelength dispersive X-ray spectroscopy (WDX) was employed to characterise MCrAlY coated superalloy samples after exposure at 1000 and 1100°C. Phases were identified by electron backscatter diffraction (EBSD) and correlated with SEM/EDX/WDX analyses.Modelling of the microstructural evolution was carried out considering simultaneously occurring surface oxidation and interdiffusion processes. A flux based calculation of the concentration profiles and stable phases was performed, taking into account diffusion of all elements in the γ, γ' and β-NiAl phases. Good agreement was found between the observed and computed phase distributions after specific time intervals. The computed widths of the β-depletion zones showed satisfactory agreement with the measurements. Additionally, the model was able to predict the formation of a TCP-phase and its penetration into the substrate with increasing exposure time in one of the investigated coating systems

The high chromium nickel base alloy 602 CA is used as construction material for high temperature components in aggressive environments such as gas burners or heat exchangers. The high temperature oxidation behaviour of this alloy is characterised by the formation of an external Cr2O3 scale and internal precipitation of alumina. The main goal of the present investigation was to elucidate the effect of aluminum on the subscale chromium depletion phenomena. The chromium concentration profiles were found to be flat and sometimes even increasing towards the oxide-alloy interface. The experimental observations were interpreted in terms of alloy thermodynamics, i.e. effect of oxidation induced compositional changes on chemical potentials of the alloy constituents. The concentration profiles in alloy 602 CA observed during high temperature exposure were modelled using the CALPHAD approach for thermodynamic and kinetic calculations. Thermodynamic calculations revealed that the Al depletion in the alloy subsurface due to internal alumina precipitation leads to enhanced Cr diffusion towards the alloy surface