The high temperature oxidation behavior of an APS processed γ-β NiCoCrAlY coating was investigated at 1150• C. Ultrathin freestanding coating specimens ranging from 16 to 240 μm in thickness were tested for short-term oxidation time (< 300 h). Intrinsic chemical failure (InCF) occurred after the full consumption of Al, and resulted in Cr 2 O 3 growth and CrN precipitation at the Al 2 O 3 /alloy interface. Mass gain slowed down after InCF, even leading to a mass loss associated with the volatilization of Cr 2 O 3 . InCF occurred after [10-20] h and [20-100] h for the ~ 21 μm and ~ 31 μm-thick specimens, respectively. Severe metal recession was observed after InCF.

This paper examines the oxidation behavior of thin specimens of cast NiCoCrAlY alloys at 1150 • C through successive stages, from Al 2 O 3 growth to complete alloy conversion to oxide. Five alloy compositions were used, with varying fractions and compositions of γ and β. The time evolution of the alloy composition during Al 2 O 3 growth was simulated using the DICTRA module of Thermo-Calc, and calculated analytically in the approximation of flat profiles. Simulated and experimental profiles were found to be in good agreement, indicating that the phase equilibrium and mass balance were correctly reproduced in the simulations. Local variations of alloy composition were observed in thinner specimens and found to be comparable with the variations expected from the uncertainty on the initial specimen thickness. The variations observed in the time-to-Al 2 O 3 failure were greater than expected on this basis, suggesting that additional sources of variability were in effect. Alumina failure was followed by the growth of a Cr 2 O 3 layer at the alloy-scale interface. Similarly, Cr consumption eventually led to Cr 2 O 3 failure, and Ni-and Co-containing spinel oxide formed, converting the Cr 2 O 3 at the alloy-scale interface and the Al 2 O 3 at the scale-gas interface. The remaining NiCo alloy was then converted to (Ni,Co)O. This sequence occurred without abrupt increase of the mass gain, due to the continued presence of the remnant Al 2 O 3 layer, and to the small amount of metal left to oxidize when the (Ni,Co)O eventually broke through the scale. The evolution of the scale composition throughout the oxidation stages is discussed based on an analysis of the thermodynamic conditions at the alloy-scale interface.