Key Takeaways & Executive Findings
- •• Double glow plasma surface alloying enables controlled columnar crystal Ni coatings with enhanced adhesion. • Interface-pinning effects achieved via layer-by-layer and island growth mechanisms improve coating-substrate bonding. • Diffusion analysis reveals comparable primary and cross-diffusion coefficients, indicating Inconel718 re-sputtering involvement. • Coating withstands 200 thermal cycles without delamination, demonstrating exceptional adhesion performance.
Abstract
Double glow plasma surface alloying was utilized to synthesize a nickel coating with controlled columnar crystalline architecture. The deposition process was systematically regulated with a fixed source electrode bias of −990 V and precisely controlled deposition temperatures (750, 800, and 850 °C) through cathode bias modulation. Plasma characteristics were quantitatively analyzed through argon emission spectroscopy, enabling precise determination of electron density and temperature. Elemental interdiffusion behavior was comprehensively characterized using electron probe microanalysis, revealing significant interface-pinning effects achieved through strategic manipulation of layer-by-layer and island growth mechanisms. Critical analysis of diffusion coefficients demonstrated comparable magnitudes between the primary diffusion coefficients, along with their cross-diffusion coefficient, suggesting substantial involvement of Inconel718 re-sputtering phenomena in the diffusion dynamics. The coating exhibited exceptional adhesion performance, maintaining structural integrity through 200 rigorous thermal cycling tests without observable delamination.
1. Introduction
Inconel718, a nickel-based superalloy, exhibits superior creep resistance and high-temperature strength, making it indispensable for manufacturing critical elastic sealing components in aircraft engines [1−4]. However, these components are susceptible to fretting corrosion on primary sealing surfaces under operational conditions involving coupled fluid−structure interactions and mechanical vibrations [5,6]. The strategic deposition of a nickel-based coating has been shown to concurrently enhance surface oxidation resistance and inhibit γ'-phase (Ni3(Ti,Al)) coarsening, a microstructural degradation mechanism directly linked to high-temperature performance deterioration [7−9].
Current Ni coating deposition techniques predominantly rely on electroplating, cold spray, and magnetron sputtering processes [10−13]. CAVALIERE et al [14] systematically investigated particle velocity effects on crystallization dynamics in cold-sprayed Ni coatings, establishing critical process−structure relationships. GENG et al [15] employed magnetron-sputtered Ni coatings to elucidate high-temperature oxidation mechanisms. Nevertheless, these conventional methods consistently demonstrate two critical limitations: insufficient interfacial adhesion strength and mismatched coefficients of thermal expansion (CTE) with Inconel718 substrates. Under cyclic stress conditions during the service, such CTE incompatibilities promote interfacial delamination, a failure mode that catastrophically degrades sealing integrity and severely limits operational lifespan in aerospace applications.
Double glow plasma surface alloying (DGPSA) emerges as an advanced surface modification technology to address these challenges. Derived from ion nitriding principles, DGPSA incorporates a hollow-cathode effect that amplifies plasma density, thereby enhancing substrate wear resistance and corrosion protection capabilities [16]. As illustrated in Fig. 1, the DGPSA system operates through continuous bombardment of the source electrode (target) by
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Shi-yu CUI, Hua-wei CHENG, Jun HUANG, Wen-ping LIANG, Luis Saucedo MORA, Joseph P. DOMBLESKY, Jun-ming LUO (2025). Enhancing adhesion in columnar crystal Ni coatings via interface-pinning structure optimization. SinoTechIntel Verified Research. https://doi.org/10.1016/S1003-6326(25)67027-0
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Frequently Asked Questions
What is the main objective of the study?
The study aims to enhance adhesion in columnar crystal Ni coatings on Inconel718 substrates via interface-pinning structure optimization using double glow plasma surface alloying.
How was the Ni coating deposited?
The Ni coating was synthesized using double glow plasma surface alloying with a fixed source electrode bias of −990 V and controlled deposition temperatures (750, 800, and 850 °C) via cathode bias modulation.
What is the significance of interface-pinning in this context?
Interface-pinning effects, achieved through strategic manipulation of layer-by-layer and island growth mechanisms, significantly improve coating-substrate adhesion by promoting interdiffusion and mechanical interlocking.
How was the adhesion performance evaluated?
Adhesion performance was evaluated through 200 rigorous thermal cycling tests, and the coating maintained structural integrity without observable delamination.
What role does Inconel718 re-sputtering play in the diffusion dynamics?
The comparable magnitudes of primary and cross-diffusion coefficients suggest substantial involvement of Inconel718 re-sputtering phenomena, which contributes to the interdiffusion behavior and interface-pinning effects.
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