Preparation of MCrAlY–Al2O3 Composite Coatings with Enhanced Oxidation Resistance through a Novel Powder Manufacturing Process

Mingwen Bai, Bo Song, Liam Reddy , Tanvir Hussain

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MCrAlY–Al2O3 composite coatings were prepared by high-velocity oxygen fuel thermal spraying with bespoke composite powder feedstock for high-temperature applications. Powder processing via a suspension route was employed to achieve a fine dispersion of α-Al2O3 submicron particles on the MCrAlY powder surface. This was, however, compromised by ~ 50% less flowability of the feedstock during spraying. Nevertheless, the novel powder manufacturing process introduced in this study has shown potential as an alternative route to prepare tailored composite powder feedstock for the production of metal matrix composites. In addition, the newly developed MCrAlY–Al2O3 composite coatings exhibited superior oxidation resistance, compared to conventional MCrAlY coatings, with the formation of nearly exclusively Al2O3 scale after isothermal oxidation at 900 °C for 10 h. The addition of α-Al2O3 particles in the MCrAlY coatings as a second phase was found to have promoted the formation of YAG oxides (YxAlyOz) during spraying and also accelerated the outwards diffusion of Al, which resulted in enhanced oxidation resistance.

Original languageEnglish
Pages (from-to)433–443
Number of pages11
JournalJournal of Thermal Spray Technology
Early online date23 Jan 2019
Publication statusPublished - 15 Feb 2019
Externally publishedYes

Bibliographical note

Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (, which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.


  • alumina
  • bond coat
  • HVOF
  • MCrAlY
  • oxidation
  • suspension


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