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

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.