L

THE AMERICAN SOCIETY OF MECHANICAL. ENGINEERS 89-GT-243

345 E. 47 St., New York, N.Y. 10017

E s The Society shall not be responsible for statements or opinions advanced in papers or in dis-
cussion at meetings of the Society or of its Divisions or Sections, or printed in its publications.
Discussion is printed only if the paper is published in an ASME Journal. Papers are available
^( from ASME for fifteen months after the meeting.
Printed in USA.
Copyright © 1989 by ASME

Rainbow Field Test of Coatings for Hot Corrosion

Protection of Gas Turbine Hot Section Components
II. Vane Coatings
MARK VAN ROODE
Solar Turbines Incorporated
San Diego, California 92101

ABSTRACT providing hot corrosion protection to FSX-414 and MAR-

A rainbow field test sponsored by the Electric Power
Research Institute (EPRI) under contract RP 2465-1 was
performed to evaluate the comparative hot corrosion
resistance of commercially available coatings for gas
turbine blades and vanes. A 10,307-hr field test was
carried out on a Solar Centaur T-4000 gas turbine
operating on a lower grade liquid fuel at the Owens-
Illinois, Inc. glass manufacturing facility in Valera,
Venezuela. This paper reviews the results of an
evaluation of the performance of a simple aluminide, a
Pt,Rh-aluminide and two MCrAIY (M = Co, NiCo) overlays
applied to the first stage FSX-414 vanes. As found for
blade coatings, on the basis of visual and metallo-
graphic examination, and remnant coating thickness
measurements, it was established that the MCrAlY
coatings were generally more effective than the simple
aluminide and the Pt,Rh-aluminide in providing protec-
tion to first stage vanes. A remnant coating thickness
index (RCTI) was used to express coating survival and
protectiveness quantitatively. The results of the study
have been compared with literature.
INTRODUCTION
This paper describes the evaluation of the compara-
tive hot corrosion resistance of gas turbine vane
coatings. It is a continuation of the study for blade
coatings discussed in a companion paper (van Roode and
Aurrecoechea, 1989). The study sponsored by the
Electric Power Research Institute (EPRI) of Palo Alto,
California, under contract RP 2465-1, addresses the
relative hot corrosion resistance of simple and modified
aluminide diffusion and MCrA1Y (M = Co, NiCo) overlay
coatings applied to the first-stage nozzle of a Centaur
T-4000 turbine operating on lower grade liquid fuels.
The coatings have been evaluated in a 10,307-hr field
test conducted at the Favianca site of the Owens-
Illinois, Inc. glass manufacturing facility in Valera,
Venezuela.
In a previous 7,940-hr rainbow field test at the
Favianca site, MCrA1X (M = Co; X = Y, Hf) overlay
coatings outperformed simple and modified aluminides in
M509 vanes.
A Cr-aluminide demonstrated better protection than
a Pt,Rh aluminide, which, in turn, outperformed a
simple aluminide on first-stage vanes. The best MCrAIX
over-lay coatings outperformed the Cr-aluminide
diffusion coating on the first-stage nozzle. Coating
performance of the overlays was observed to improve
with increasing Cr-content (van Roode et al., 1987; van
Roode, 1988).
A limited number of vane coatings was examined for
the second test described here. The coatings evaluated
were a simple aluminide, a Pt,Rh-modified aluminide, a
Co-300r-8Al-0.3Y overlay coating applied by low-pres-
sure plasma spraying (LPPS) and a Ni-33Co-28Cr-8Al-0.3Y
overlay coating applied by electron beam-physical vapor
deposition (EB-PVD). The vane alloy was FSX-414.
This paper describes the hot corrosion performance
of the vane coatings and reviews Solar's experience
with diffusion aluminides and overlay coatings for
turbine blades and vanes accumulated from the two rain-
bow tests completed to date.
VANE ALLOY AND COATINGS SELECTION AND CHARACTERIZATION
Vane Alloy
All coatings were applied to FSX-414, the standard
nozzle material for the Centaur T-4000 turbine. The
Centaur T-4000 first-stage nozzle consists of 22 two-
airfoil segments. The nominal composition for FSX-414
is given in Table 1.
The vane material was examined metallographically
as part of the microstructural evaluation of the as-
received coated nozzle segments to ensure that the
TABLE 1. CHEMICAL COMPOSITION OF FSX-414
(WEIGHT PERCENT)
C = 0.25 Cr = 29.0 Fe = 0.68
Mn = 0.480 Ni = 10.6 W = 7.2
Si = 0.91 Co = Bal. B = 0.008

Presented at the Gas Turbine and Aeroengine Congress and Exposition—June 4-8, 1989—Toronto, Ontario, Canada

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 07/20/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 ■

TABLE 2. VANE COATINGS

Set Number of Coating Coating

Number _ Substrate Vane Scents _ Vane I.D. Canposition Designation Application Supplier
)

1 FSX-414 5 1,2,11,12,13 Ni-33Co-28Cr-8A1-0.3Y NiCoCrA1Y EB-PVD Airco Temescal

2 FSX-414 5 3,4,5,14,15 Co-30Cr-8A1-0.3Y CoCrAIY LPPS Chromalloy R&T

3 FSX-414 5 6,7,16,17,18 Pt,Rh-Aluminide RT-44 Electroplate Chromalloy R&T

& Diffusion

4 FSX-414 7 8,9,10,19,20 Aluminide H9-109 Diffusion Solar

21,22

1 E6-PVD: coating applied by electron beam-physical vapor deposition

LPPS: coating applied by low pressure plasma spray

::1i
desired alloy microstructure was present. A stabilized
a-free matrix phase with Chinese script carbides of 2B 18
refractory elements was observed as expected.

Vane Coatings 1A
The vane coatings listed in Table 2 were applied to
the first-stage nozzle segments by the suppliers.
Two to four identically coated vanes were arranged
adjacent to each other. Groups of identically coated
vanes were placed opposite each other in the nozzle
assembly. The order of the coated segments is listed in 1C
Table 2. F iC G
Three of the four coating systems were also used in
a previous rainbow test (van Roode, et al., 1987; van
Roode, 1988), simple aluminide (H9-109), Pt,Rh-aluminide
(RT-44), and Co-30Cr-8Al-0.3Y (LPPS CoCrA1Y). The Ni-
33Co-28Cr-8Al-0.3Y (EB-PVD NiCoCrA1Y) coating had not
been evaluated as a vane coating in the first rainbow
test but this composition was included because of its
good performance as a blade coating. The EB-PVD G
NiCoCrA1Y was also included as a blade coating in the
second rainbow test.
Specimens for metallographic examination were FIG. 1 SECTIONING PLAN FOR NOZZLES. CUPS TAKEN FROM
prepared using the sectioning plan of Figure 1. AIRFOILS PARALLEL TO SHROUL (1A, 2A, 2B, AND
Sections parallel to the shrouds were taken from the 2C) AND P ARALLEL TO AIRFOIL EDGES (1B AND 1C).
center of the two airfoils (1A and 2A) and at the tip SECTIONS TAKEN FROM OU'T'ER. (F) AND INNER (G)
and base of one airfoil at 1/8-inch from the shroud SHROUDS.
surface (2B and 2C). Two sections were made parallel to
the airfoil edges 1B and 1C). Sections through the Large variations in thicknesses were observed for
outer shroud (F) and inner shroud (G) were also the LPPS Co-30Cr-8A1-0.3Y and EB-PVD Ni-33Co-28Cr-8Al-
prepared. 0.3Y coatings. As expected for coatings deposited
using a line-of-sight process, the regions between the
Thickness of As-Received Coati_nng air-foils, i.e., Section lA-concave (pressure side) and
Coating thicknesses, determined to provide a Sections 2A, 2B, and 2C convex (suction side) have
baseline for life cycle data, are listed in Table 3. lower average coating thicknesses than the opposite
The values listed are of measurements taken at equi- sides of the airfoil. The shroud Sections 1B, 1C, F,
distant locations on specimen mounts. A total of 10 and G also have lower average coating thicknesses.
measuring points were used to obtain average for each of
the convex (suction) and concave (pressure) sides of ENGINE TEST
airfoil Sections 1A, 2A, 2B and 2C. The number of
measurement points for Sections 1B and 1C was 6; for Details of the 10,307-hr engine test have been
Section F it was 12, and 9 locations were used to obtain reported in the companion paper (van Roode and
the average thickness for location G. Aurrecoechea, 1989).
It can be seen that the average thickness values for
the diffusion aluminides is significantly lower than COATING PERFORMANCE EVALUATION
that for the MCrA1Y overlays. The average thickness of
the simple aluminide (H9-109) was somewhat less than of Visual Examinati on
the Pt,Rh-aluminide (RT-44). The thicknesses were Findings from visual examination of nozzle segments
generally fairly uniform, although large variations were following the 10,307-hr field test have been compiled
occasionally noted (e.g., Section F of RT-44). in Table 4. Corrosion pitting was observed on all

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 07/20/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 ■

TABLE 3. VANE COATING THICKNESS DATA

As-Coated After Field Test

Remnant Coating
Convex2 Concave2 Convex2 Concave2 Thickness Index

Coating/Substrate Section Avg. Range Avg. Range Avg. Range Avg. Range Convex Concave Average

Aluminide IA 17 15-19 16 14-19 0 0-0 0 0-0 0.00 0.00 0.01'

H9-109/FSX-41 2A 17 13-22 17 15-20 1 0-11 0 0-0 0.06 0.00
2B 17 14-20 19 15-31 0 0-0 1 0-11 0.00 0.05
2C
1B
15
16
12-19
14-17 --
14 12-17 0
3
0-0
0-10
---
0 0-0 0.00
0.18
0.00
0.254
1C
F
G
15
16
16
12-18
12-20
14-18
-- 4
8
1
0-12
0-13
0-12 -
0.27
0.50
0.06

Pt,Rh-Aluminide 1A 20 18-21 19 17-22 16 0-22 10 0-21 0.80 0.91 0.503

RT-44/FSX-414 2A 19 18-21 18 15-21 14 0-23 2 0-22 0.74 0.18
2B 20 18-21 18 17-21 4 0-23 2 0-22 0.20 0.11
2C
1B
19
19
17-23
18-21 --
18 14-20 11
13
0-19
0-21
8 0-21 0.58
0.68
0.44
0.454

--
1C 17 19-22 10 0-20 0.59
F 13 0-23 7 0-24 0.54
G 20 19-22 0 0-0 0.00

Co-30Cr-8A1-0.3Y/ 1A 54 51-60 30 11-51 58 51-63 34 28-48 1.07 1.13 0.993

FSX-414 LPPS 2A 31 7-45 59 54-62 45 18-60 54 46-59 1.45 0.92
2B 35 8-51 66 55-72 38 9-56 32 0-59 1.09 0.48
2C 36 8-49 61 55-66 37 11-50 47 0-66 1.03 0.77
1B 42 31-50 45 32-62 1.07 0.874
1C 40 16-57 32 0-62 0.80
F 29 0-71 24 0-71 0.83
G 32 7-63 25 0-63 0.78

Ni-33Co-28Cr-8A1-0.3Y/ 1A 55 49-63 25 13-41 63 0-85 19 0-57 1.15 0.76 1.103

FSX-414 EB-PVD 2A 36 14-54 57 48-67 55 14-90 40 0-77 1.53 0.70
2B 27 7-53 52 44-63 46 0-78 29 0-45 1.70 0.88
2C 24 7-41 42 29-65 47 9-88 33 0-69 1.96 0.79
1B 30 23-50 41 25-71 1.37 1.624
1C 22 8-50 44 7-93 2.00
F 18 0-54 27 0-82 1.50
G 18 5-52 29 11-75 1.61

'Thickness in in. x 10 -4 , average over all locations of a section

2 For sections 1A, 2A, 2B, and 2C only
3 Sections 1A, 2A, 2B, 2C
4 Sections 1B, 1C, F, G

TABLE 4. VISUAL OBSERVATIONS ON COATED VANES AFTER 10,307 HOUR ENGINE TEST

Vane I.D. Coating Observations

1,2,11,12,13 Ni-33Co-28Cr-8Al-0.3Y Heavy pitting on airfoil pressure sides and leading edges, and
EB-PVD shrouds (1,2,11,12), white deposits (1,12).

3,4,5,14,15 Co-30Cr-8Al-0.3Y Moderate pitting on airfoil pressure sides, leading edges, and
LPPS airfoil/shroud junctions at pressure side, white deposits (4,5).

6,7,16,17,18 Pt,Rh-Aluminide Heavy pitting on airfoil pressure sides and leading edges, and
(RT-44) shrouds, white purple deposits on airfoil pressure sides
(16,17,18), brown deposits on airfoils and shrouds.

8,9,10,19,20,21,22 Aluminide Heavy pitting on all areas of airfoils and shrouds, white deposits
(H9-109) (10,19).

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 07/20/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 0

apes, but it was more extensive on the aluminides. For Remnant Coating Thickness index (RCTI) =
the MCrAlY overlays, pitting damage was more severe for
the EB-PVD NiCoCrA1Y when compared with the LPPS Ave rage Remnant Coating Thickness After Field Test
CoCrAlY. The latter coating showed extensive corrosion Average Remnant Coating Thickness of As-Coated
degradation at the airfoil/shroud junction at the Specimens
pressure side. This corrosion pattern was also observed
at the airfoil/platform junction (pressure side) for TABLE 5. CHEhMICAL ANALYSIS DATA'
this coating on first-stage blades (van Roode and
Aurrecoechea, 1989).
An example of a section of the first stage nozzle White Deposits Brown Areas
with the EB-PVD Ni-33Co-28Cr-8A1-0.3Y coated vane
segments is shown in Figure 2. The typical extended Al 2.61 0.17
areas of corrosion pitting have developed from near Ca 25.90 0.65
circular initial pattern. Photographs of nozzle Co 5.53 0.32
segments coated with each of the four coatings of Table Cr 1.04 0.36
2 are shown in Figure 3. Fe 8.29 43.14
K 1.36 0.11
Mg 2.18 9.97
Na 19.58 0.86
Ni 2.03 1.17
0 Hal Hal
S2 1.13 1.00

I
Si 1.02 1.97
w - -

Zn 4.30 7.25

lAnalyzed by atomic absorption.

2 Analyzed by a combustion technique.

An examination of the RCTI values shows a definite

FIG. 2 EB-PVD Ni-33Co-28Cr-8A1-0.3Y COATED SECTIONS OF
FIRST STAGE NOZZLE AFTER 10,307-HR FIELD TEST
Deposits of a predominantly white color were
observed on a number of nozzle segments. Areas with a
rust brown color were prevalent on the airfoil suction
sides and shrouds. Results of chemical analysis, of
composite samples from several nozzle segments are shown
in Table 5. A high content of Na was found in the white
deposits. It is surmised that these deposits were
largely responsible for the hot corrosion of the vane
segments. The elements Co and Ni originate from the
coating or the substrate. The brown deposits are
predominantly Fe-oxides as the high Fe content suggests.
The source of this element could have been the
combustor. Alternatively, it would have been
transported from outside the hot section together with
Ca, Mg, and Zn which were also detected in high
concentrations.
Remnant Coating Thic kne ss Measurements
Coating survival and alloy substrate protection was
quantitatively estimated using remnant coating thick-
ness measurements on metallographic mounts sectioned
following the pattern of Figure 1. Remnant coating
thickness data for each of the four nozzle segments of
Figure 3 are listed in Table 3 together with the data
for as-received vanes. Detailed data showing remnant
coating thickness at each measurement location will be
included in a future EPRI report. Remnant coating
thicknesses were measured as described by McMinn, 1985.
Coating survival and substrate protection has been
expressed using the remnant coating thickness index
defined previously for the blade coatings (van Roode and
Aurrecoechea, 1989).
increase in coating survivai when comparing the Pt,Rh-
aluminide (RT-44) with the simple aluminide (H9-109).
The MCrAlY overlay coatings have higher RCTI values
than RT-44. However, the high RCTI values (in excess
of 1.00) observed for some of the sections of the LPPS
CoCrAlY and for the EB-PVD NiCoCrA1Y overlay suggests
that there was a substantial variation in as-coated
thickness between individual nozzle segments. Since
visual observations indicated that in general the LPPS
CoCrA1Y had less degradation than the EB-PVD NiCoCrA1Y
the higher RCTI values for the latter coating system
reflect to some extent the variation in initial coating
thickness of the as-received coated vanes.
On the basis of RCTI values alone coating survival
and substrate protection appears to increase in the
sequence
H9-109 < RT-44 < LPPS Co-30Cr-8Al-0.3Y
< EB-PVD Ni-33Co-28Cr-8A1-0.3Y.
Metallographic Examination
The metallographic mounts sectioned according to
Figure 1 were also used to examine the microstructure
of the above coatings after the 10,307-hr field test.
The metallographic observations have been summarized in
Table 6.
The simple aluminide, H9-109, afforded little
protection to FSX-414 vanes over the duration of the
field test under the hot corrosion conditions at the
Favianca site. Coating degradation had been severe at
the airfoils with little coating remaining and severe
corrosion penetration of the vane alloy substrate. The
coating had been more protective at the outer shroud
but corrosion degradation at the inner shroud had been
severe. The corrosion morphology is typical for Type 1
hot corrosion with a broken up metal substrate, grain
boundary attack, and sulfide precipitates. The predom-
inant element in the corrosion layers is Cr. EDX
analysis of residual coating at the suction side of
Section 2A (Figure 4) indicates Al and Cr to be the

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 07/20/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use



Pressure Side Suction Side Pressure Side Suction Side

A. H9-109 (9) B. RT-44 (17)

^ r
r p !^

Pressure Side Suction Side Pressure Side Suction Side

C. LPPS Co30Cr-8A1-0.3Y (4) D. EB-PVD Ni-33Co-28Cr-8A1-0.3Y (12)

Number in brackets: Sequence of vane segment in first-stage nozzle

FIG. 3 COATED FIRST STAGE VANES AFTER 10,307-HR ENGINE TEST

1 NON T

r
FIG. 4 SEM MICROGRAPH AND EDX SCANS OF H9-109 COATED FSX-414 AFTER 10,307-HR FIELD TEST. VANE NO. 9.
SECTION 2A, R.ESIDUAL COATING AT CENTER OF SUCTION SIDE

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 07/20/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use


U

TABLE 6. OBSERVATIONS FROM METALLOGRAPHY OF COATED VANES AFTER 10,307-HR FIELD TEST

Vane Vane
Number All oy Vane_ Composition Air foils and Sub strate s Shrou d s

9 FSX-414 Aluminide Severe coating and substrate degrada-
(H9-109) tion, little coating remaining near
trailing edge, Al/Cr surface corro-
sion layer, broken up substrate metal,
grain boundary attack, sulfide
precipitates.
Inner shroud: severe degradation
Outer shroud: coating degradation near
airfoil junction.
Multi-(Co/Cr) layer corrosion deposits,
sulfide precipitates.

17 FSX-414 Pt,Rh-Aluminide Severe coating and substrate degrada- Moderate coating degradation.
(RT-44) tion at pressure sides and leading
edges, Fe surface deposits, Al/Cr
corrosion layers, broken up substrate
metal, grain boundary attack, Cr-
depletion, sulfide precipitates.

4 FSX-414 Co-30Cr-8A1-0.3Y Coating degradation at leading edges Minor coating degradation, Fe/Zn sur-
LPPS and at airfoil/shroud junctions, Fe face deposits, cracks with Cr corrosion
surface deposits, Al/Cr corrosion deposits at junction with airfoil,
deposits at surface and throughout sulfide precipitates in coating.
coating, coating and substrate degra-
dation near shrouds with thick multi-
(Co/Cr) layer corrosion deposit.

12 FSX-414 Ni-33Co-28Cr- Coating degradation at leading edges Minor coating degradation.

8A1-0.3Y and pressure sides, Fe/Zn surface
deposits, numerous transverse cracks
in coating, Al corrosion deposits.

major elements in the surface corrosion layer. The
elemental distribution of the residual coating is
similar to that of the as-received coating.
Figure 5 shows the heavily corroded leading edge of
airfoil Section 1A of Pt,Rh-aluminide (RT-44) coated
FSX-414. As for the H9-109 coated FSX-414 airfoil, the
hot corrosion morphology is Type 1. Regions of sub-
strate depleted in Cr, Cr-rich areas at the corroded
grain boundaries, and sulfide precipitates are observed.
Figure 6 shows severely corroded residual coating. An
Fe-rich surface deposit overlays the corrosion layer in
which Al is the predominant element. An Al-rich zone
separates the remnant coating from the alloy substrate.
It is likely that this Al-rich zone (Al203?) plays a
role in the coating degradation process by providing a
site for debonding and spallation. Smaller Al-rich
corrosion deposits were observed throughout the coating.
The LPPS Co-30Cr-8A1-0.3Y overlay coating has
afforded relatively good hot corrosion protection to the
nozzle segments. Figure 7 shows the coating to be
largely intact at the leading edge of vane airfoil
section 2A. Corrosion was observed at the surface and
throughout the interior of the coating. Figure 8 shows
substantial corrosion degradation of the coating at the
airfoil/shroud junction of Section F (suction side).
The coating shows several transverse cracks with heavy
Cr-rich corrosion deposits. EDX analysis of internal
corrosion deposits in the coating shows Cr to be the
predominant element. Sulfide precipitates were also
observed in the coating. Extended coating degradation
and substrate penetration had occurred at several
locations on the airfoils near the leading edges and
shrouds. Figure 9 shows a voluminous multilayer
corrosion deposit with Co and Cr as the predominant
elements, located on Section 2B at the pressure side.
The corrosion morphology is typical for Type 2 hot
corrosion.
The EB-PVD Ni-33Ci-28Cr-8Al-0.3Y overlay coating
was somewhat less protective on vane airfoils than the
LPPS Co- 30Cr-8A1-0.3Y. Hot corrosion degradation at
the leading edges and pressure sides was substantial.
Figure 10 shows a thick corrosion layer with Cr and Al
as the main constituents next to intact coating. The
coating showed numerous cracks along the grain bound-
aries (Figure 11). Corrosion of the cracked coating
was especially severe where the thickness of the coat-
ing was low. The example shown in Figure 12 of the
suction side of airfoil section 2B indicates that
corrosion has penetrated into the substrate. The main
constituent of the corrosion layer is Al.
DISCUSSION
Comparison of Two _Rai nbow Fi eld Tests
As for the blade coatings discussed in the com-
panion paper (van Roode and Aurrecoechea, 1989) the
vane coatings investigated in the 10,307-hr rainbow
field test confirm the results for similar coatings
examined in the first 7,940-hr field test (van Roode et
al., 1987; van Roode, 1988).
In general, the two MCrA1Y overlay coatings perform
better than the simple and Pt,Rh-aluminide in terms of
coating retention. It must be pointed out that a
comparison of RCTI values alone may obscure the true
protectiveness of the coatings because of possible
large variations in as-received coating thickness for
the EB-PVD Ni-33Co-28Cr-8A1-0.3Y overlay.
Using RCTI average values alone, the EB-PVD
NiCoCrA1Y coating appears to be the most protective.
Including visual and metallographic observations,
however, vanes coated with the LPPS Co- 30Cr-8A1-0.3Y
coating show definitely less evidence of hot corrosion
degradation.

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 07/20/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 in

50u0FS 100. T
0000FS i00• T

20 KU
W
MAG:40OX

mss:' $Q

NI

d , N Ck
' NI
p Cn S
FE
F W

0.0 2 6 4.0 U 3.0 10.1

4.0 6.0 8.0 10 0
E14E022 tIOU
ENERGY [ KEV)
10E 00 F) 10i_UU ^T
10000FS ?02 T

0 10 0

FIG. 5 SEM MICROGRAPHS AND EDX SCANS OF RT-44 COATED FSX-414 AFTER 10,307-HR FIELD TEST. VANE NO. 17.
(A) SECTION 1A, LEADING EDGE. (B) CLOSE-UP SHOWING GRAIN BOUNDARY ATTACK AND SULFIDE PRECIPITATES

On the basis of visual observations, metallographic corrosion was, however, established at the airfoil near
examination and remnant coating thickness measurements the vicinity with the shrouds (Figure 9).
the coating survival and substrate protectiveness In the comparison paper (van Roode and
increases in the sequence. Aurrecoechea, 1989), blade airfoil temperatures were
estimated using the Y'-coarsening method (Kolkman,
Aluminide (H9-109) < Pt,Rh-aluminide (RT-44) 1981) and the results were compared with design values.
< EB-PVD Ni-33Co-28Cr-8A1-0.3Y No accepted metallographic method exists to estimate
< LPPS Co-30Cr-8A1-0.3Y. the temperatures of Co-base vane alloys. Vane temper-
atures based on analytical calculations are more
The corrosion morphology in areas where the coating difficult to obtain because of the more complex design
has severely degraded is predominantly Type 1 as of a nozzle vane compared to a rotor blade. However,
evidenced by the presence of a broken-up substrate metal temperatures of nozzle vanes have been determined
surface, sulfide precipitates (Figures 5 and 8) and the experimentally for the cooled first-stage nozzles in
absence of voluminous oxide layers. Evidence of Type 2 engine tests. Engine test results indicate that the

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 07/20/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 106• i

I \ I 1

1, 1, a 4 e E 0 so l so 0 .y tl I L: n
EHEPI,Y iKEV? Etl E R GY t K=EUi

FIG. 6 SEM MICROGRAPHS AND EDX SCANS OF RT-44 COATED FSX-414 AFTER 10,307-HR FIELD TEST. VANE NO. 17.
(A) SECTION 1A, CENTER OF PRESSURE SIDE. (B) CLOSE-UP SHOWING Fe SURFACE DEPOSIT AND Al-RICH
COATING/SUBSTRATE INTERFACE.

first-stage nozzle vane of the Centaur T-4000 engine is The superior hot corrosion protection of the Pt,Rh-
not expected to exceed a temperature of 810 ° C. This aluminide (RT-44) over the simple aluminide (H9-109)
measured maximum value is consistent with a turbine confirms the results established in the first rainbow
rotor inlet temperature (TRIT) of 870`C and a pattern test. The average coating thickness, slightly greater
factor of 0.25. The shroud sections of the nozzle vanes for RT-44 (Table 3), can be expected to improve coating
can be expected to have temperatures well below 810 ° C. survival to some extent. More likely, the presence of
In view of the known temperature ranges for Type 1 hot Pt and Rh is expected to contribute to the enhanced
corrosion (800 ° to 1000 ° C) and Type 2 hot corrosion corrosion protectiveness of RT-44 when compared with
(600 ° to 750 ° C) evidence of both types of hot corrosion the simple aluminide.
morphology can, therefore, be expected.

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 07/20/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 I

10000FS 100. T

20 KU

C. K

41 4S I4J4

FIG. 7 SEM MICROGRAPH OF LPPS Co-30Cr-8A1-0.3Y COATED

FSX-414 AFTER 10,307—HR FIELD TEST. VANE NO. 4
SECTION 2A, LEADING EDGE

0
cn
6000FS 100N T E N s FE zra
LR Oil N

UK UK 4K 64 80 1 04
ENERG'f [KE0

MG --J
'1,yb - B
ZN C0

0 0 2 0 4.0 6-0 8.0 10.0

ENERGY ( KEU)

Lam] 0 40 -' KM 1 0 0
ENERGY r6EU

FIG. 8 SEM MICROGRAPHS AND EDX SCANS OF LPPS Co-30Cr-8A1-0.3Y COATED FSX-414 AFTER 10,307—HR FIELD TEST.
VANE NO. 4. (A) SECTION F AT AIRFOIL/SHROUD JUNCTION, SUCTION SIDE. (B) CLOSE—UP SHOWING Cr
CORROSIONN DEPOSITS AND SULFIDE PRECIPITATES.

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 07/20/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 0

FIG. 9 SEM MICROGRAPH OF LPPS Co-30Cr-8A1-0.3Y COATED FIG. 11 OPTICAL MICROGRAPH OF EB-PVD Ni-33Co-28Cr-
FSX-414 AFTER 10,307-HR FIELD TEST. 8A1-0.3Y COATED FSX-414 AFTER 10,307-HR
VANE NO. 4, SECTION 2B, PRESSURE SIDE FIELD TEST. VANE NO. 12, SECTION 2B,
TRAILING EDGE

=_st0eeFS RRU T
bYt HL iE CU
^f ^C

C. R
TI S TI Ck

O 0 _ e / 4 6 E a .
.E 10 u
ENERGI' ._k EV)

FIG. 10 SEM MICROGRAPH OF EB-PVD Ni-33Co-28Cr-8A1-0.3Y

COATED FSX-414 AFTER 10,307-HR FIELD TEST.
VANE NO. 12, SECTION 2B, PRESSURE SIDE

The LPPS Co-30Cr-8A1-0.3Y vane coating was ranked

second after an EB-PVD Co-30r-l0A1-0.3Y overlay in the '-
7,940-hr field test (van Roode, 1988). The EB-PVD Co-
33Cr-28Cr-8A1-0.3Y vane coating was not evaluated in the
first rainbow test. The inferior performance of the EB-
PVD NiCoCrA1Y when compared with the LPPS CoCrA1Y in the
10,307-hr test might be attributable to the somewhat
lower Cr content of the former coating, since a correla- a
tion of coating protectiveness with Cr level was estab-
lished in the first rainbow test. However, the superior
performance of the EB-PVD NiCoCrAlY as a blade coating
makes this factor somewhat less plausible. Differences
in as-received coating thickness at the airfoil pressure
side, may also account for the lower protectiveness of
the EB-PVD NiCoCrA1Y as a vane coating.
Another important factor is the pattern of the
corrosion damage. The process of corrosion degradation FIG. 12 SEM MICROGRAPH AND EDX SCAN OF EB-PVD Ni-
for the vane coatings studied is different. The Pt,Rh- 33Co-28Cr-8A1-0.3Y COATED FSX-414 AFTER
aluminide coating appears to degrade to a large extent 10,307-HR FIELD TEST. VANE NO. 12,
through corrosion of the 13-CoAl phase in the surface SECTION 2B, SUCTION SIDE

10

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 07/20/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use


layer and through debonding along an Al203/Cr203
interface formed between coating and substrate alloy.
Surface and internal corrosion appears to be the
predominant degradation mode for the LPPS CoCrA1Y
coating. Both the LPPS CoCrAlY and the EB-PVD NiCoCrAlY
coating also form large patchlike corrosion pits through
lateral corrosion of the coating and inward degradation
of the substrate. Also, corrosion along grain boun-
daries appears to be a contributing factor to degrada-
tion of the EB-PVD coating.
Comparison of Blade and Vane Coatings Performance wi th
Literature Data
The two rainbow field tests performed under the EPRI
hot section coatings program have shown clear trends in
performance for hot corrosion protection of blade and
vane coatings. (van Roode, et al., 1987; van Roode,
1988; van Roode and Aurrecoechea, 1989). Briefly
summarized, these trends are:
1. MCrA1Y (M = Co, NiCo) overlays with high
concentrations of Cr (28-30%) perform
significantly better than simple and modified
(Cr-, Pt/Rh-) aluminides in providing hot
corrosion protection to nickel-and cobalt-base
alloys in the turbine hot section in the low-
temperature (Type 2) and intermediate (Type 1/2)
hot corrosion regimes.
2. Differences are observed in coating perfor-
mance between various MCrAIY (M = Co, NiCo)
overlays for Type 2 and Type 1/2 (interme-
diate) hot corrosion conditions. It is
difficult to establish whether variations in
coating thickness, Cr content, or coating
microstructure are responsible for these
differences in coating protectiveness.
3. Increasing the Cr-content of MCrAIX (M = Co; X =
Y, Hf) overlay coatings improves Type 1/2 hot
corrosion protectiveness.
4. Pt-modified aluminides perform significantly
better as coatings for hot corrosion protec-
tion under Type 1 conditions than under Type 1/2
and Type 2 conditions.
5. A Cr-aluminide and a NiCoCrA1Y/ZrO2-20Y203
duplex overlay performed poorly as a blade
coating over the entire range of Type 1 to Type
2 conditions.
A comparison of the results of this 10,307-hr field
test and of the first 7,940-hr rainbow test conducted
under the EPRI sponsored program with the results of
other studies will necessarily be limited because of the
specific environmental and operating conditions of each
test. Still, such a comparison is valuable because
broad trends may become apparent, which will aid the
coating selection process in future applications.
The superior hot corrosion resistance of the MCrAIX
(M = Co, NiCo; X = Y, Hf) overlays observed in the two
rainbow tests of the EPRI program is not generally
reported by other investigators. Several studies have
reported better or equivalent hot corrosion resistance
for some Pt-aluminides and Pt,Rh-aluminides when
compared with CoCrAlY's (Aprigliano and Wacker, 1976;
Davis and Grinnell, 1982; McMinn, 1985; McMinn, 1988).
The common factor in these studies appears to be that
the CoCrA1Y's had a low to intermediate Cr content (Cr
< 25%). Note that MCrAIX (M = Co; X = Y, Hf overlays)
with lower Cr contents (23 to 26%) investigated in the
11
Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 07/20/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use
a
previous 7,940-hr rainbow test afforded substantially
less hot corrosion resistance to Co-base vane alloys
compared to CoCrA1Y compositions with 30% Cr (van Roode
et al., 1987; van Roode, 1988). The importance of the
Cr content for the hot corrosion resistance of MCrA1Y
(M = Ni, Co) overlays has been demonstrated in a number
of other studies as well. (Aprigliano, 1978; Goebel,
1979; Giggins and Fenton, 1980; Conde et al., 1982;
Luthra and Wood, 1984).
In selecting overlay coatings for the rainbow test,
it was assumed that both Type 1 and Type 2 hot corro-
sion conditions would be present in the hot section of
the engine. Both Al and Cr are essential elements in a
protective overlay system because Type 1 hot corrosion
depends on Al203 for protection, while Type 2 hot
corrosion requires Cr203 for protection. Cr203 is leas
effective in the high-temperature (Type 1) regime
because of its tendency to convert to volatile chrome
oxides, while Al203 is ineffective at the low temper-
ature (Type 2) regime because of the rapid acidic
fluxing of this species in an oxide scale. Although
Cr203 by itself does not afford significant Type 1 hot
corrosion protection, the presence of Cr as an overlay
is useful because it lowers the requirement for Al in
the coating.
For good overall hot corrosion protection, a compo-
sition with a high Cr content (> 30%) and an inter-
mediate Al content ( 10%) is optimal (Kubarych, 1984;
-
van Roode, 1988). The MCrAlY coatings used in the
second (10,307-hr) rainbow test had Cr (28 to 30%) and
Al (8 to 10%) contents close to these optimal values.
The Ni-base blade alloys MAR-M421 and IN-738LC used in
this program have a Cr level of about 16% and an Al
level of about 3 to 4%. Thus, the MCrA1Y's provide a
significant increase in the levels of Cr and Al
compared to the Ni-base blade alloys. The Cr level of
Co-base FSX-414 is 29.0% and Al is absent in this vane
alloy. The MCrA1Y's are therefore, expected to be more
effective in providing Type 1 hot corrosion resistance
(Al,Cr-dependent) for FSX-414 than in improving the
Type 2 hot corrosion resistance (Cr-dependent) of this
alloy. Ideally, a higher Cr content (> 35%) would be
preferred for a coating on Co-base alloys such as FSX-
414 in view of the potentially improved Type 2 hot
corrosion resistance. However, this amount of Cr
appears to be too high for maintaining good coating
ductility and the levels of Cr (28 to 30%) in the
MCrAlY overlays selected for the second (10,307-hr)
rainbow test were preferred.
An examination of remnant coating thickness values
and coating microstructure of coated MAR-M421 blades
showed less difference in hot corrosion resistance for
Pt-aluminides (RT-22A, (LDC-2E) and MCrAlY (M = Co,
NiCo) overlays at the upper blade sections where Type 1
hot corrosion is prevalent. The Pt-aluminides showed
inferior hot corrosion resistance compared to the
MCrAlY (M = Co, NiCo) overlays in the intermediate Type
1/2 hot corrosion regimens of the lower blade airfoil
sections and platforms (van Roode and Aurrecoechea,
1989). Other studies have indicated that the presence
of Pt significantly improves the high-temperature hot
corrosion resistance of simple aluminides, but that Pt
is not as beneficial at low temperatures (EPRI AP-1369,
1980; Wood et al., 1982; Davis and Grinnell, 1982; Wu
et al., 1984; Deb and Boone, 1985; Bauer et a].., 1985;
Dust et al. 1986; Goward and Cannon, 1987). A number
of studies have indicated that a continuous PtAl2 layer
is a prerequisite for good low-temperature hot corro-
sion resistance while a two-phase PtAl2/f3-NiAl struc-
ture performs little better than simple aluminides on
Ni-base alloys (Barkalow and Pettit, 1978; Wing and
McGill, 1981; Wu et al., 1984; Streiff and Boone, 1985,

Dust et al., 1986; Goward and Cannon, 1987). It is
surmised that the two-phase PtAlz/f3-NiA1 structure at
the outer layer of the RT-22A and LDC-2E blade coatings
is responsible for the inferior performance of the Pt-
aluminides in the areas of the blade airfoil and
platform where Type 2 hot corrosion has been observed.
SUMMARY AND CONCLUSIONS
A simple aluminide, a Pt,Rh-aluminide, and two
MCrA1Y (M = Co, Ni) overlay coatings were investigated
for hot corrosion (alkali metal sulfate) resistance on
FSX-414 first-stage turbine vanes of a Solar Centaur T-
4000 engine in a 10,307-hr rainbow field test at the
Favianca Owens-Illinois, Inc. glass plant in Valera
Venezuela. The coated components were studied by visual
and metallographic examination upon completion of the
field test. Remnant coating thickness measurements were
performed and a quantitative estimate of coating
survival and substrate protection was obtained. The
data have been compared with those of a previously
reported 7,940-hr field test conducted at the Favianca
site.
As observed for blade coatings of similar generic
compositions MCrAIY (M = Co, NiCo) overlays performed
better than simple and modified aluminides. On the
basis of visual observations, calculated RCTI values and
microstructural examination, the coatings can be ranked
in order of increasing coating survival and substrate
protectiveness under conditions that show aspects of
both Type 1 and Type 2 hot corrosion as follows:
Aluminide (H9-109) < Pt,Rh-aluminide (RT-44)
< EB-PVD Ni-33Co-28Cr-8A1-0.3Y
< LPPS Co-30Cr-8A1-0.3Y
The author wishes to acknowledge the technical
support of Robert W. Frischmuth of the Electric Power
Research Institute for the work reported herein.
Aprigliano, L. and Wacker, G., 1976, "Laboratory and
Service Evaluation of the Hot Corrosion Resistance of
Precious Metal Duplex Coatings," Proceedings of the
Third Conference on Gas Turbine Materials in a Marine
Environment, Session III, Paper 4, Bath, U.K.
Aprigliano, L.F., 1978, "Low Temperature (1300 ° F)
Burner Rig Test of MCrA1Y Composition Variations,"
DTNSRDC Report TM28-78/218.
Barkalow, R.H., and Pettit, F.S., 1975, 'Degrada-
tion of Coating Alloys in a Marine Environment," Report.
FR-10225, U.S. Navy Contract No. N000173-73-C-04146.
Bauer, R., Schneider, K, and Grunling, H.W., 1985,
"Experience with Platinum Aluminide Coatings in Land-
Based Gas Turbines," High Temperature Technology, Vol.
2, pp. 59-64.
Conde, J.F.G., Booth, G.C., Taylor, A.F., and
McGreath G.C., 1982, "Hot Corrosion in Marine Gas
Turbines," Proceedings of Conference on High Tempera-
ture Alloys for Gas Turbines, COST 50, pp. 237-247.
Davis, F.N., and Grinnell, C.E., 1982, "Engine
Experience of Turbine Rotor Blade Materials and
Coatings," ASME Paper 82-GT-244, London, U.K.
Deb, P., and Boone, D.H., 1985, "Microstructural
Formations and Effects on the Performance of Platinum
Modified Aluminum Coatings," Office of Naval Research
Contract N0001425WR24098, Final Report 1981-1985, Naval
Postgraduate School.
12
Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 07/20/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use
0
Dust, M.W., Deb, P., Boone, D.H., and Shankar, S.,
1986 "Hot Corrosion Resistance of Chromium Modified
Platinum-Aluminide Coatings," ASME Paper 86-GR-291,
Dusseldorf, West Germany.
Dist, M.W., Deb, P., Boone, D.H., and Shankar, S.,
1986, "Structure and 700`C Hot Corrosion Behavior of
Chromium Modified Platinum-Aluminide Coatings," J. Vac.
Sci. Technol. A, Vol. 4 (6), pp. 2571-2576.
Electric Power Research Institute, 1980, "Parameter
Monitoring for Corrosion Control of Utility Gas
Turbines," Annual Report, EPRI Report, AP-1369, Project
643-1.
Giggins, C.S., and Fenton, R.J., 1980, "Metallic
Coating Development and Evaluation Program," Naval Sea
Systems Command Contract No. N00024-78-C-5337, Seventh
Quarterly Technical Report.
Goebel, J.A., 1979, "Advanced Coating Development
for Industrial/Utility Gas Turbine Engines," Proceed-
ings of the First Conference on Advanced Materials for
Alternative Fuel Capable Direct Fired Heat Engines,
IX)E-EPRI, Castine, ME, pp. 473-488.
Goward, G.W., and Cannon, L.W., 1987, "Pack
Cementation Coatings for Superalloys. A Review of
History, Theory and Practice," ASME Paper 87-GT-50,
Anaheim, California.
Kolkman, H.J., 1981, "Coarsening and Solutioning of
Precipitates in Superalloys," NRL TR 8111 4, National
Aerospace Laboratory (NLR), Amsterdam, The Netherlands.
Kubarych, K.G., 1984, "Evaluation of Performance of
Gas Turbine Blade Coatings," EPRI Research Project
2388-1, Interim Report.
Kubarych, K.G., Boone, D.H., and Duncan, R.L.,
1984, "Long-Term Field Test of Advanced Gas Turbine
Airfoil Coatings under a Severe Industrial
Environment," ASME Gas Turbine Conference Paper No. 84-
GT-277, Amsterdam, The Netherlands.
Luthra, K.L., and Wood, J.L., 1984, "High Chromium
Cobalt-Base Coatings for Low Temperature Hot
Corrosion," Thin Solid Films, Vol. 119, pp. 271-280.
McMinn, A., 1985, "Evaluation of Protective
Coatings for Hot Components of Combustion Turbines,"
Electric Power Research Institute, Final Report, AP-
4194, Project 2380-3.
McMinn, A., 1988, "Evaluation of Protective
Coatings for Hot Components of Combustion Turbines,"
Electric Power Research Institute, Final Report, RP
2388-4.
Streiff, R., and Boone, U.H., 1985, "The Modified
Aluminum Coatings - Formation Mechanisms of Cr and Pt
Modified Coatings," Reactivity of Solids, Elsevier
Science Publisher, B. V., pp. 195-198.
van Roode,, M., Kubarych, K.G., and McCarron, R.L.,
1987, "Rainbow Field Test of Coatings for Hot Corrosion
Protection of Gas Turbine Hot Section Components," ASME
Gas Turbine Conference Paper No. 87-GT-130, Anaheim,
California.
van Roode, M., 1988, "Rainbow Test of Advanced
Coatings for Gas Turbine Blades and Vanes," EPRI - AP-
5965, Research Project 2465-1, Interim Report.
van Roode, M., and Aurrecoechea, J., 1989, "Rainbow
Field Test of Coatings for Hot Corrosion Protection of
Gas Turbine Blades and Vanes. I. Blade Coatings," ASME
Gas Turbine Conference Paper, Toronto, Canada, in
press.
Wing, R.G., and McGill, I.R., 1981, "Protection of
Gas Turbine Blades," Platinum Met. Rev., Vol. 25(3),
pp. 94.
Wood, J.H., Schilling, W.F., and Aesbacher, H.J.,
1982 "Evaluation of Gas Turbine Bucket Corrosion
Protection Systems Following Long-Term Service in Saudi
Arabia," ASME Paper 82-GT-99, London, U.K.
 a

Wu, W.T., Rahmel, A., and Schorr, M., 1984, "Role of

Platinum in the Na2SO4-Induced Hot Corrosion Resistance
of Aluminum Diffusion Coatings," Oxidation of Metais,
Vol. 22 (1,2), pp. 59-81.

13

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 07/20/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use