Evaluation of Structural and Phase Stability of Multi-Component Heat-Resistant Coatings Based on Alloyed Iron and Nickel Aluminides

This study investigates the synthesis, phase evolution, and high-temperature oxidation behavior of multi-component aluminide coatings on EP670 (Fe-Ni base), EP718 (Ni-Fe base), and EP648 (Ni-base) superalloys. The coatings were produced using an economical hot-dip aluminizing method, followed by diffusion heat treatment at 1100 °C. In the as-deposited state, the coatings exhibit a heterogeneous structure consisting of an aluminum matrix with various Al-rich intermetallic inclusions. Subsequent heat treatment promotes the redistribution of chemical elements, leading to the elimination of free aluminum and the stabilization of a protective β-phase matrix. Long-term oxidation tests were performed at 900 °C, 1100 °C, and 1300 °C for up to 1000 h. At 1100 °C, the coatings on EP670 and EP648 demonstrated high stability, following a near-parabolic oxidation law and significantly reducing mass gain compared to uncoated substrates. However, at 1100 °C, the EP718 alloy underwent catastrophic failure within 200 h due to pest oxidation, disintegrating into an oxide powder—a phenomenon quantitatively confirmed by the kinetic exponent dropping below 1.0. At 1300 °C, the thermal limit for all coatings was established, with protective properties failing after 50 h. Based on the aluminum depletion kinetics, the service life at 1100 °C was estimated at 1300 h for EP670 and 2200 h for EP648. Scratch testing confirmed a complete absence of interfacial adhesive cracks across all systems. Contact loading triggered only cohesive cracks localized within the near-surface zone of the coatings. The results highlight the superior thermodynamic compatibility of the EP670 and EP648 systems with aluminide coatings, making them the most suitable candidates for extreme high-temperature applications.