Authors: F.I. Panteleenko, O. Devoino, V.V. Okovity, V.Yu. Blumenstein

Title of the article: Review of modern application of composite materials based on nickel alloys with ceramics systems for forming multilayer composite plasma coatings. Part 1

Year: 2026, Issue: 2, Pages: 45-55

Branch of knowledge: 2.6.1 Metal science and heat treatment of metals and alloys

Index UDK: 621.793.7:621.762

DOI: 10.26730/1999-4125-2026-2-45-55

Abstract: The article provides an overview of the modern application of composite materials based on nickel alloys with ceramics systems for the formation of multilayer composite plasma coatings. Metal alloys based on MCrAlY material are very often used as a functional external coating or a bonding coating in the plasma spraying process and are very useful in protecting surfaces from destruction under high-temperature exposure on components of operating parts. A new area of ​​application of these coatings can be obtained by adding particles of new materials to the basic MCrAlY metal matrix to create composite coatings. Thermal spray composite coatings MCrAlY with enhanced functional properties due to the addition of reinforcing elements such as yttrium-stabilized zirconium dioxide (YSZ) (ZrO2-8Y2O3), CeO2, Al2O3-TiO2, Al2O3, zirconium dioxide (CSZ) (ZrO2-25CeO2-2.5Y2O3) are characterized by enhanced mechanical properties, corrosion and thermal resistance. However, insufficient strength bond between oxides and metal matrix, crack formation, chipping, porosity are typical disadvantages of thermal spray coatings. To reduce these defects and improve the strength characteristics of the coating, various options for subsequent high-energy processing using a laser or compression plasma are used. The addition of rare earth element (REE) stabilized oxide ceramics to MCrAlY coatings can significantly improve both wear resistance and corrosion resistance of the coatings. REEs, being surface-active elements, reduce the surface tension and interfacial energy between the crystal core and the melt during solidification, which leads to improved wetting properties and a decrease in the contact angle between the melt and the substrate. In recent years, rare earth elements have been successfully used to modify the surface properties of thermal spray coatings. The addition of REE to the coatings results in grain refinement and grain boundary cleaning, which increases the microhardness and wear resistance of the coatings, and reduces the friction coefficient.

Key words: composite material nickel-chromium-aluminum-yttrium oxide ceramics plasma spraying durability and reliability of mechanisms heating rate of powder particles diffusion of molten salts hot corrosion

Receiving date: 30.12.2025

Approval date: 15.05.2026

Publication date: 29.06.2026

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