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Electrochemical Processing of Layered Composite Coatings of Nickel - Aluminum - Alumina / Alumina - Yttria Stabilized Zirconia

Published online by Cambridge University Press:  10 February 2011

K. Barmak
Affiliation:
Department of Materials Science and Engineering, Lehigh University, Bethlehem, PA 18015
S. W. Banovic
Affiliation:
Department of Materials Science and Engineering, Lehigh University, Bethlehem, PA 18015
H. M. Chan
Affiliation:
Department of Materials Science and Engineering, Lehigh University, Bethlehem, PA 18015
L. E. Friedersdorf
Affiliation:
Department of Materials Science and Engineering, Lehigh University, Bethlehem, PA 18015
M. P. Harmer
Affiliation:
Department of Materials Science and Engineering, Lehigh University, Bethlehem, PA 18015
A. R. Marder
Affiliation:
Department of Materials Science and Engineering, Lehigh University, Bethlehem, PA 18015
C. M. Petronis
Affiliation:
Department of Materials Science and Engineering, Lehigh University, Bethlehem, PA 18015
D. G. Puerta
Affiliation:
Department of Materials Science and Engineering, Lehigh University, Bethlehem, PA 18015
D. F. Susan
Affiliation:
Department of Materials Science and Engineering, Lehigh University, Bethlehem, PA 18015
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Abstract

Multilayered coatings of single and dual particle metal matrix composites, with or without ceramic overlayers, have been produced by a novel combination of electrochemical deposition (electroplating and electrophoretic deposition) and reaction bonding. The coatings contain the following layers in a variety of combinations deposited on Ni substrates: (i) electroplated composites of Ni with Al and/or alumina particles, (ii) precursor Al + A12O3 + yttria stabilized ZrO2 transformed into A12O3 + yttria stabilized ZrO2 by the reaction bonding method, and (iii) yttria stabilized ZrO2. In order to determine the appropriate processing parameters for the multilayered coatings, uniform one-layer coatings were deposited and characterized. We find that in the dual particle Ni-Al-Al2O3 coatings the volume percent of the particles does not show a dependence on deposition current density. However, volume percent alumina in these coatings has a strong dependence on the amount of this particle in the plating bath, while the volume percent Al shows only a weak dependence on its bath content. Comparison of the deposition behavior of these dual particle with single particle coatings, containing Al or alumina only, reveals that the presence of Al in the bath interferes with the codeposition of alumina. This interference, however, is not reciprocal. When coatings containing Al are annealed, Ni and Al react to form a solid solution of Al in Ni (γ) or a two phase mixture of this solid solution and the intermetallic, Ni3Al, (γ-γ') depending on the annealing temperature. Finally, we find that the formation of the reaction bonded alumina plus yttria stabilized zirconia layer requires the oxidation resistance afforded by aluminum in the underlying electroplated layer.

Type
Research Article
Copyright
Copyright © Materials Research Society 1997

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References

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