Improved alumina scale adhesion of electron beam physical vapor deposited Dy/Hf-doped β-NiAl coatings

The cyclic oxidation behavior of Dy/Hf-doped β-NiAl coatings produced by electron beam physical vapor deposition (EB-PVD) was investigated. For the undoped NiAl coating, numerous voids were formed at the alumina scale/coating interface and large rumpling developed in the scale, leading to premature oxide spallation. The addition of Dy and Hf both improved scale adhesion and the alumina scale grown on the NiAl-Hf coating showed better adhesion than that on the NiAl-Dy coating, although the suppressing effect on interfacial void formation and the scale rumpling resistance were stronger in the NiAl-Dy coating. It is proposed that the segregation of Dy and Hf ions at the scale/coating interfaces not only prevent interfacial sulfur segregation but also may directly enhance interfacial adhesion by participating in bonding across the interfaces, and this strengthening effect is relatively stronger for Hf ionic segregation.