Long-Term Oxidation Behavior of Supersonic Plasma-Sprayed NiCrAlY Coatings in SOFC System

Qinghu Ge; Xuesong Shen; Xianzeng Zhong; Cuiwei Du; Hongchi Ma; Xiaogang Li

doi:10.1007/s11665-025-12221-2

Long-Term Oxidation Behavior of Supersonic Plasma-Sprayed NiCrAlY Coatings in SOFC System

Qinghu Ge
, Xuesong Shen^*
, Xianzeng Zhong
, Cuiwei Du
, Hongchi Ma^*
, Xiaogang Li

^*Corresponding author for this work

University of Science and Technology Beijing
Shandong Guochuang Fuel Cell Technology Innovation Center Co., Ltd.

Research output: Contribution to journal › Article › peer-review

Abstract

In this work, two kinds of NiCrAlY coating with different porosities were prepared on the surface of 310S stainless steel using supersonic plasma spraying technology. The long-term field exposure test in the SOFC system revealed that the supersonic plasma-sprayed NiCrAlY coating exhibited excellent oxidation resistance in the SOFC environment containing O₂ and water vapor. The well-prepared coatings showed only slight interfacial oxidation after 10,000 h, indicating their potential as candidate materials in the SOFC system. The oxidation resistance and anti-stripping performance of the NiCrAlY coating in the SOFC environment is significantly influenced by the porosity of the coating. Coatings with higher porosity tend to form clusters of Cr- and Al-rich oxides in the coating, which led to interfacial delamination at the coating/substrate interface.

Original language	English
Pages (from-to)	7800-7812
Number of pages	13
Journal	Journal of Materials Engineering and Performance
Volume	35
Issue number	8
DOIs	https://doi.org/10.1007/s11665-025-12221-2
State	Published - Feb 2026
Externally published	Yes

Keywords

High-temperature oxidation
NiCrAlY
SOFC
interfacial delamination
supersonic plasma-sprayed coating

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10.1007/s11665-025-12221-2

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title = "Long-Term Oxidation Behavior of Supersonic Plasma-Sprayed NiCrAlY Coatings in SOFC System",

abstract = "In this work, two kinds of NiCrAlY coating with different porosities were prepared on the surface of 310S stainless steel using supersonic plasma spraying technology. The long-term field exposure test in the SOFC system revealed that the supersonic plasma-sprayed NiCrAlY coating exhibited excellent oxidation resistance in the SOFC environment containing O2 and water vapor. The well-prepared coatings showed only slight interfacial oxidation after 10,000 h, indicating their potential as candidate materials in the SOFC system. The oxidation resistance and anti-stripping performance of the NiCrAlY coating in the SOFC environment is significantly influenced by the porosity of the coating. Coatings with higher porosity tend to form clusters of Cr- and Al-rich oxides in the coating, which led to interfacial delamination at the coating/substrate interface.",

keywords = "High-temperature oxidation, NiCrAlY, SOFC, interfacial delamination, supersonic plasma-sprayed coating",

author = "Qinghu Ge and Xuesong Shen and Xianzeng Zhong and Cuiwei Du and Hongchi Ma and Xiaogang Li",

note = "Publisher Copyright: {\textcopyright} ASM International 2025.",

year = "2026",

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doi = "10.1007/s11665-025-12221-2",

language = "英语",

volume = "35",

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TY - JOUR

T1 - Long-Term Oxidation Behavior of Supersonic Plasma-Sprayed NiCrAlY Coatings in SOFC System

AU - Ge, Qinghu

AU - Shen, Xuesong

AU - Zhong, Xianzeng

AU - Du, Cuiwei

AU - Ma, Hongchi

AU - Li, Xiaogang

N1 - Publisher Copyright: © ASM International 2025.

PY - 2026/2

Y1 - 2026/2

N2 - In this work, two kinds of NiCrAlY coating with different porosities were prepared on the surface of 310S stainless steel using supersonic plasma spraying technology. The long-term field exposure test in the SOFC system revealed that the supersonic plasma-sprayed NiCrAlY coating exhibited excellent oxidation resistance in the SOFC environment containing O2 and water vapor. The well-prepared coatings showed only slight interfacial oxidation after 10,000 h, indicating their potential as candidate materials in the SOFC system. The oxidation resistance and anti-stripping performance of the NiCrAlY coating in the SOFC environment is significantly influenced by the porosity of the coating. Coatings with higher porosity tend to form clusters of Cr- and Al-rich oxides in the coating, which led to interfacial delamination at the coating/substrate interface.

AB - In this work, two kinds of NiCrAlY coating with different porosities were prepared on the surface of 310S stainless steel using supersonic plasma spraying technology. The long-term field exposure test in the SOFC system revealed that the supersonic plasma-sprayed NiCrAlY coating exhibited excellent oxidation resistance in the SOFC environment containing O2 and water vapor. The well-prepared coatings showed only slight interfacial oxidation after 10,000 h, indicating their potential as candidate materials in the SOFC system. The oxidation resistance and anti-stripping performance of the NiCrAlY coating in the SOFC environment is significantly influenced by the porosity of the coating. Coatings with higher porosity tend to form clusters of Cr- and Al-rich oxides in the coating, which led to interfacial delamination at the coating/substrate interface.

KW - High-temperature oxidation

KW - NiCrAlY

KW - SOFC

KW - interfacial delamination

KW - supersonic plasma-sprayed coating

UR - https://www.scopus.com/pages/publications/105018768150

U2 - 10.1007/s11665-025-12221-2

DO - 10.1007/s11665-025-12221-2

M3 - 文章

AN - SCOPUS:105018768150

SN - 1059-9495

VL - 35

SP - 7800

EP - 7812

JO - Journal of Materials Engineering and Performance

JF - Journal of Materials Engineering and Performance

IS - 8

ER -

Long-Term Oxidation Behavior of Supersonic Plasma-Sprayed NiCrAlY Coatings in SOFC System

Abstract

Keywords

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