• Journal of Powder Materials
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• v.28 no.3
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• pp.201-207
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• 2021

Ni-Cr-Al metal-foam-supported catalysts for steam methane reforming (SMR) are manufactured by applying a catalytic Ni/Al₂O₃ sol-gel coating to powder alloyed metallic foam. The structure, microstructure, mechanical stability, and hydrogen yield efficiency of the obtained catalysts are evaluated. The structural and microstructural characteristics show that the catalyst is well coated on the open-pore Ni-Cr-Al foam without cracks or spallation. The measured compressive yield strengths are 2-3 MPa at room temperature and 1.5-2.2 MPa at 750℃ regardless of sample size. The specimens exhibit a weight loss of up to 9-10% at elevated temperature owing to the spallation of the Ni/Al₂O₃ catalyst. However, the metal-foam-supported catalyst appears to have higher mechanical stability than ceramic pellet catalysts. In SMR simulations tests, a methane conversion ratio of up to 96% is obtained with a high hydrogen yield efficiency of 82%.

• Journal of Surface Science and Engineering
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• v.52 no.6
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• pp.283-288
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• 2019

MCrAlY overaly coatings are used as oxidation barrier coatings to prevent degradation of the underlying substrate in high temperature and oxidizing environment of the hot section of gas turbines. Therefore, oxidation resistance in high temperature is important property of MCrAlY coatings. Also, coefficients of thermal expansion (CTE) of MCrAlY have middle value of that of Ni-based superalloys and oxides, which have the effect of preventing the delamination of the surface oxides. Cyclic oxidation test is one of the most useful methods for evaluating the high temperature durability of coatings used in gas turbines. In this study, NiCoCrAlY overlay coatings were formed on Inconel 792(IN 792) substrates by vacuum plasma spraying process. Vacuum plasma sprayed NiCoCrAlY coatings and IN 792 susbstrates were exposed to 1000℃ one-hour cyclic oxidation environment. NiCoCrAlY coatings showed lower weight gain in short-term oxidation. In long-term oxidation, IN 792 substrates showed higher weight loss due to delamination of surface oxide but NiCoCrAlY coatings showed lower weight loss. X-ray diffraction (XRD) analysis showed α-Al2O3 and NiCr₂O₄ was formed during the cyclic oxidation test. Through cross-section observation using scanning electron microscopy (SEM) and electron back scatter diffraction (EBSD) analysis, thermally grown oxide (TGO) layer composed of α-Al₂O₃ and NiCr₂O₄ was formed and the thickness of TGO increased during 1000℃ cyclic oxidation test. β phase in upper side of NiCoCrAlY coating was depleted due to oxidation of Al and outer beta depletion zone thickness also increased as the cyclic oxidation time increased.

• Journal of Surface Science and Engineering
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• v.31 no.2
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• pp.81-90
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• 1998

NiCrAly/YSZ(8wt% Y2O3-Zro2) functionally fraded thermal barrier coating (FGC) layers on a Co-base sureralloy (HAYNESS 188) substrate were fabricated using Ar shielded single torch air plasma spraying method. Functional grading were produced with the stepwise compositional change throughout layer thinkness. Microstructural observation revealed a sucessful fabrication of NiCrAly/YSZ FGC. From the results of the curvature measurement, adhesive stength measurement and thermal shock test for the FGC, it was concluded that the optimum enhance of functionally graded coating layer thinkcess and compositional pattern exit to enhance the properties of FGC, which is closely reated to the internal residual distribution with it.

• Korean Journal of Materials Research
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• v.25 no.8
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• pp.391-397
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• 2015

NiO catalysts/$Al_2O_3$/FeCrAl alloy foam for hydrogen production was prepared using atomic layer deposition (ALD) and subsequent dip-coating methods. FeCrAl alloy foam and $Al_2O_3$ inter-layer were used as catalyst supports. To improve the dispersion and stability of NiO catalysts, an $Al_2O_3$ inter-layer was introduced and their thickness was systematically controlled to 0, 20, 50 and 80 nm using an ALD technique. The structural, chemical bonding and morphological properties (including dispersion) of the NiO catalysts/$Al_2O_3$/FeCrAl alloy foam were characterized by X-ray diffraction, X-ray photoelectron spectroscopy, field-emission scanning electron microscopy and scanning electron microscopy-energy dispersive spectroscopy. In particular, to evaluate the stability of the NiO catalysts grown on $Al_2O_3$/FeCrAl alloy foam, chronoamperometry tests were performed and then the ingredient amounts of electrolytes were analyzed via inductively coupled plasma spectrometer. We found that the introduction of $Al_2O_3$ inter-layer improved the dispersion and stability of the NiO catalysts on the supports. Thus, when an $Al_2O_3$ inter-layer with a 80 nm thickness was grown between the FeCrAl alloy foam and the NiO catalysts, it indicated improved dispersion and stability of the NiO catalysts compared to the other samples. The performance improvement can be explained by optimum thickness of $Al_2O_3$ inter-layer resulting from the role of a passivation layer.

• Proceedings of the Korean Institute of Surface Engineering Conference
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• 2014.11a
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• pp.215-215
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• 2014

Composites layer of Al-Cr-Ni-O system was prepared on a steel plate by hydro-thermal process at $700^{\circ}C$ for 12 hours, which phase identification and thermal conductivity were determined. The composites layer consisted of aluminum nitride, alumina, chromium carbide and aluminium, which density was $3.7kg/m^3$. The thermal conductivity of the coating layer determined by thermal data acquisition system was about 98.0 W/m/ which depended on the AlN content. Numerical modelling of the heat transfer behavior of the coating layer was well agreement with the empirical data.

• Journal of Powder Materials
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• v.20 no.6
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• pp.460-466
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• 2013

4 mol% Yttria-stabilized zirconia (4YSZ) coatings with $200{\mu}m$ thick are fabricated by Electron Beam Physical Vapor Deposition (EB-PVD) for thermal barrier coating (TBC). $150{\mu}m$ of NiCrAlY based bond coat is prepared by conventional APS (Air Plasma Spray) method on the NiCrCoAl alloy substrate before deposition of top coating. 4 mol% YSZ top coating shows typical tetragonal phase and columnar structure due to vapor phase deposition process. The adhesion strength of coating is measured about 40 MPa. There is no delamination or cracking of coatings after thermal cyclic fatigue and shock test at $850^{\circ}C$.

• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09a
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• pp.511-512
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• 2006

Tungsten coatings with different interlayers onto the oxygen-free copper substrates were fabricated by atmosphere plasma spraying. The effects of different interlayers of NiCrAl, NiAl and W/Cu on bonding strength were studied. SEM, EDS and XRD were used to investigate the photographs and compositions of these coatings. The tungsten coatings with different initial particle sizes resulted in different microstructures. Oxidation was not detected in the tungsten coating, but in the interlayer, it was found by both XRD and EDS. The tungsten coating deposited directly onto the copper substrate presented higher bonding strength than those with different interlayers.

• Journal of Hydrogen and New Energy
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• v.21 no.6
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• pp.500-506
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• 2010

The metal monolith catalyst coated with 15wt% Ni/$MgAl_2O_4$ is applied to the natural gas steam reforming for hydrogen production. To address the improvement of adherence between metal monolith and catalyst coating layer, the pre-calcination temperature as well as the coating conditions of $Al_2O_3$ sol are optimized. When the Fe-Cr alloy monolith is pre-calcined at $900^{\circ}C$ for 6 h, $Al_2O_3$ layer was formed uniformly on the entire surface of the metal substrate. It is seen that the formation of $Al_2O_3$ layer on the monolith surface is essential for the uniform coating of $Al_2O_3$ sol onto the monolith substrate. The monolith catalyst coated with 10wt% $Al_2O_3$ sol shows high $CH_4$ conversion and good thermal stability as compared with the monolith catalyst without $Al_2O_3$ sol coating under severe reaction conditions with high GHSV of 30,000 $h^{-1}$ at $700^{\circ}C$. In addition, the metal monolith catalyst shows higher catalytic activity and better thermal conductivity than 15wt% Ni/$MgAl_2O_4$ pellet catalyst.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.38 no.6
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• pp.629-636
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• 2014

For surface modification, bulk metallic glass coatings were fabricated using metallic glass powder and a mixture of a self-fluxing alloy or/and hard metal alloys with a heat-resisting property using a high velocity oxy-fuel coating thermal spraying process. Microstructural analyses and mechanical tests were carried out using X-ray diffraction, a scanning electron microscope, an atomic force microscope, a three-dimensional optical profiler, and nanoindenation. As a result, the monolithic metallic glass coating was found to consist of solid particle and lamellae regions that included many pores. Second phase-reinforced composite coatings with a self-fluxing alloy or/and hard metal alloy additives were employed with in-situ $Cr_2Ni_3$ precipitate or/and ex-situ WC particles in an amorphous matrix. The mechanical behaviors of the solid particles and lamella regions showed large hardness and elastic modulus differences. The mechanical properties of the particle regions in the metallic glass composite coatings were superior to those of the lamellae regions in the monolithic metallic glass coatings, but indicated similar trends in matrix region of all the coating layers.

• Korean Journal of Materials Research
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• v.4 no.2
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• pp.166-176
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• 1994

Ni base superalloys are composed of solid sohltion hardening elements(Co, Cr. Mo. W and so on) and $\gamma '$ precipitation hardening elements(A1, Ti, Nb, Ta and so on). To Improve the mechanical properties and oxidation resistanre of superalloys, rare earth elements(%r, Hf, Y and so on) are added to the inner substrate, or are used as coating materials. Their pffects on the growth rate and adhes~on of oxide are changed according to the kinds of oxides such as $AI_2O_3$ and $Cr_2O_3$. The effect of yttrium on the oxidation rate, grain size of oxide, internal structure, and crack resistance was investigated for two kinds of Ni-base superalloys. One in AF'115 superalloy containing Hf and the other is MA6000 superalloy containing $Y_2O_3$. They werr owid~zed at high temperature after yttrium surface modification using ion coater. Yttrium coating on the AF115 and MA6000 superalloys results in a marked change in the growth of the inner oxide. For AF115 superalloy, the degree of gram boundary segregation of $Cr_2O_3$, and prefer en^ tial oxidation of Hf are decreased, and the shape of inner oxidation layer was changed from triangle to plate type. For MA6000 superalloy, $Cr_2O_3$ oxide scale was transformed as outer oxidation layer of CrZOI and inner oxidation layer of $Cr_2O_3$.