Skip to main content
SpringerLink
Log in

Oxidation of Ferrous Alloys and Coatings Under Isothermal, Impulse Heating, and Diesel Engine Operation: Part II—MCrAlY Coatings for Protection of 4140 Steel

  • Original Paper
  • Published:
Oxidation of Metals Aims and scope Submit manuscript

Abstract

The use of nickel- and iron-based alloy coatings containing Cr, Al, and Y (NiCrAlY and FeCrAlY) were evaluated as potential oxidation barriers for low-alloy steels for the next generation of high-output diesel engines. Rapid oxidation at temperatures above 500 °C currently limits the use of the 4140 steels used to manufacture pistons crowns in this application. Isothermal furnace testing, a novel highly transient combustion-based laboratory test, and direct high temperature engine exposure were used to assess the efficacy of the coating-substrate systems. Both NiCrAlY and FeCrAlY coatings appear to protect the substrate from oxidation at isothermal temperatures up to 677 °C. On direct exposure to combustion, through Impulse Cyclic Heating Tests, the NiCrAlY coatings themselves also appear resistant to degradation at very high temperatures, while the FeCrAlY coatings degrade more rapidly for equivalent thermal loading. Engine tests further validated the efficacy of NiCrAlY coatings, with neither coatings nor 4140 steel pistons showing degradation at temperatures estimated to be more than 500 °C. From this work NiCrAlY coatings are estimated to have a potential upper limit of 677 °C, at which interdiffusion between the coating and substrate will likely complicate their use.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

References

  1. J. Saputo, F.Caliari , E.Gingrich , M. Tess , S. Sampath, Oxidation of Metals. (in press).

  2. D. Pierce, J. Haynes, J. Hughes, et al., High Temperature Materials for Heavy Duty Diesel Engines: Historical and Future Trends. Progress in Materials Science 103, 109 (2019).

    Article  CAS  Google Scholar 

  3. E. Gingrich, D. Pierce, M. Tess et al., SAE Technical Paper. 2022–01–0599 (2022)

  4. H. J. Williams and W. E. Ballard, Journal of the Institution of Production Engineers 16, 251 (1937).

    Article  Google Scholar 

  5. E. Cady, Scientific American 176, 201 (1947).

    Article  Google Scholar 

  6. F. J. Centolanzi , NASA Technical Memorandum X-620, 15 (1971)

  7. S. Kaminaka, Journal of Medical Instrument 16, 1 (1938).

    Google Scholar 

  8. J. Sannier, R. Dominget, and R. Darras, J. Nuclear Materials 3, 212 (1959).

    Google Scholar 

  9. E. Gulbransen and K. F. Andre, Journal of the Electrochemical Society, 106, 941 (1959).

    Article  CAS  Google Scholar 

  10. S.Grisaffe, Protective Coatings for Superalloys. Aerospace Structural Materials Proceedings, 305–316 (1969).

  11. F. P. Talboom, R. C. Elam , L. W. Wilson, Evaluation of Advanced Superalloy Protection Systems. Final report. No. NASA-CR-72813. 1970.

  12. R. C. Tucker, Summary of the Seventeenth Refractory Composites Working Group, Williamsburg, VA, (1970).

  13. G. W. Goward, Surf Coat Technol. 108, 73 (1998).

    Article  Google Scholar 

  14. F. J. Hermanke, All About “Emcrawlees.” J Therm Spray Technol. 9, 315 (2000).

    Google Scholar 

  15. E. Bodmann, D. Diehl , I. Blume-Firla, H. Demus, In: Proceedings of A Specialists Meeting Organized by the International Atomic Energy Agency. Cracow, Poland, (1988).

  16. M. G. Hocking, Surf Coat Tehcnol. 62, 460 (1993).

    Article  CAS  Google Scholar 

  17. I. A. Kvernes and P. Fartum, Thin Solid Films. 53, 259 (1978).

    Article  CAS  Google Scholar 

  18. D Zhu, R. A. Miller, Evaluation of Oxidation Damage in Thermal Barrier Coating Systems. NASA Technical Memorandum, 107360 (1996).

  19. M. B. Beardsley, Thick Thermal Barrier Coatings (TTBCs) for Low Emission, High Efficiency Diesel Engine Components. USDOE Report 22580–1, Caterpillar Inc., Peoria (2006).

  20. D. Dickey , S. Vinyard , R. Keribar, The Effect of Insulated Combustion Chamber Surfaces on Direct-Injected Diesel Engine Performance, Emissions and Combustion. NASA Technical Memorandum, CR-182204 (1988).

  21. W. Lineton , M. Azevedo, Thermal Oxidation Protective Surface for Steel Pistons. US Patent # 7458358 (2008).

  22. N. Uchida, . International Journal of Engine Research 23 (2020).

    Google Scholar 

  23. E. Gingrich, M. Tess , G. J. Korivi, International Journal of Engine Research (2021).

  24. D. R. Tree, P. Wiczynski, and T. M. Yonushonis, SAE Transactions 105, 112 (1996 ).

    Google Scholar 

  25. E. Gingrich, M. Tess, V. Korivi, P. Schihl, J. Saputo, G. Smith, S. Sampath, and J. Ghandhi, The Impact of Piston Thermal Barrier Coating Roughness on High-load Diesel Operation. International Journal of Engine Research 22, 1239 (2021).

    Article  Google Scholar 

  26. J. Schindelin, I. Arganda-Carreras, E. Frise, et al., Fiji: Nature Methods 9, 676 (2012).

    Article  CAS  Google Scholar 

  27. Standard Procedure for Measuring and Compensating for Emissivity Using Infrared Imaging Radiometers. E1933–14, Annual Book of ASTM Standards, Part 0.3.03, (2018)

  28. Y. C. Chen , J. Worden, Evaluation of Microalloyed Steel for Articulated Piston Applications in Heavy Duty Diesel Engines. SAE Technical Paper: 200–01–1232m, (2000).

  29. K. Hirano, M. Cohen, and B. L. Averbach, Acta Metallurgica 9, 440 (1961).

    Article  CAS  Google Scholar 

  30. A. W. Bowen and G. M. Leak, Metallurgical Transactions, 1, 2767 (1970).

    Article  CAS  Google Scholar 

  31. B. Chattopadhyay and G. C. Wood, J. Electrochem. Soc. 117, 1163 (1970).

    Article  CAS  Google Scholar 

  32. N. Otsuka, Y. Shida, and H. Fujikawa, Oxidation of Metals 32, 13 (1989).

    Article  CAS  Google Scholar 

  33. M. Auinger, V. G. Praig, B. Linder, and H. Danninger, Grain boundary oxidation in iron-based alloys, investigated by 18O enriched water vapor—The effect of mixed oxides in binary and ternary Fe-{Al, Cr, Mn, Si} systems. Corrosion Science 96, 133 (2015).

    Article  CAS  Google Scholar 

  34. J. Ruzickova and B. Million, Materials Science and Engineering 50, 59 (1981).

    Article  CAS  Google Scholar 

Download references

Acknowledgements

This work was funded by Army In-House Laboratory Independent Research (ILIR) basic research funds in coordination with the Office of Naval Research grant N00014-20-1-2700 to Stony Brook University. The authors would like to thank Mr. Carl Schmidt for his assistance in the preparation of coatings, Mr. Steven Stoll for his mechanical expertise in acquiring engine data, Dr. James Quinn for his assistance in EDAX collection and data processing, and all other individuals in GVSC’s propulsion laboratory and the CTSR that made this work possible.

Author information

Authors and Affiliations

  1. Center for Thermal Spray Research, Stony Brook University, 130 Heavy Engineering Bldg, Stony Brook, NY, 11794-2275, USA

    Felipe Caliari, John Saputo & Sanjay Sampath

  2. U.S. Army Ground Vehicle System Center, 6501 E. 11 Mile Road, Warren, MI, 48397, USA

    Eric Gingrich & Michael Tess

Authors
  1. Felipe Caliari
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. John Saputo
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Eric Gingrich
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Michael Tess
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Sanjay Sampath
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Felipe Caliari.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Caliari, F., Saputo, J., Gingrich, E. et al. Oxidation of Ferrous Alloys and Coatings Under Isothermal, Impulse Heating, and Diesel Engine Operation: Part II—MCrAlY Coatings for Protection of 4140 Steel. Oxid Met 98, 471–488 (2022). https://doi.org/10.1007/s11085-022-10132-4

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11085-022-10132-4

Keywords

Search

Navigation