Dans le secteur aéronautique en pleine expansion, les préoccupations environnementales prennent une place de plus en plus importante. Les motoristes recherchent des solutions innovantes pour augmenter les rendements tout en diminuant les coûts. Dans cette perspective, de nouveaux systèmes de barrières thermiques synthétisés par la voie sol-gel à partir de poudres commerciales, de céramiques avec différents facteurs de forme et d'agents porogènes ont été mis en œuvre et évalués. Certains systèmes présentent une durée de vie de plus de 1000 cycles en oxydation cyclique. Malgré tout, cet accroissement des températures de fonctionnement des moteurs, induit une élévation des températures de surfaces des barrières thermiques et peut générer de nouvelles dégradations du système complet : la corrosion à hautes températures par les CMAS. Pour pallier ces inconvénients, il est possible de développer des revêtements anti-CMAS, susceptibles de réagir avec les composés CMAS avant qu'ils n'aient un effet néfaste sur l'intégrité de la barrière thermique. Dans cette étude, nous nous sommes intéressés particulièrement aux revêtements sacrificiels anti-CMAS à base d'yttrine et de systèmes pyrochlore, qui ont été testés sur des barrières thermiques industrielles de type EBPVD. Par ailleurs, les procédés que nous avons développés, basés sur la voie sol-gel, nous permettent, de par leur facilité de mise en œuvre, d'envisager des perspectives prometteuses en termes de réparabilité des barrières thermiques endommagées. En effet, compte tenu du coût élevé de fabrication des pièces, les aubes devraient être réparées plusieurs fois avant d'être mises au rebut. Dans ce travail, un procédé de mise en forme a été évalué dans ce sens. Il s'agit de l'électrophorèse qui est une technique bien adaptée au dépôt sur pièces complexes. L'objectif de ces investigations a donc été double : tout d'abord créer de nouveaux systèmes de barrières thermiques avec des propriétés anti-CMAS par électrophorèse puis réparer les barrières thermiques EBPVD endommagées et leur déposer une couche protectrice anti-CMAS par ce même procédé. Cet aspect " procédé " sera abordé en dernière partie de ces travaux. / In the aeronautics sector, environmental concerns are becoming increasingly important. Engine manufacturers are looking for innovative solutions to increase efficiency while lowering costs. The objective is to optimize thermal conductivity and durability with the cyclic oxidation resistance. In this perspective, new thermal barrier systems synthesized by the sol-gel route from commercial powders, ceramics with various form factors and pore-forming agents have been implemented and evaluated. Some systems are a lifetime higher than 1000 cycles in cyclic oxidation. However, this increase in the operating temperatures of the engines induces an increase in the temperature of the surfaces of the thermal barriers and can generate further degradations of the complete system: the corrosion by CMAS. To overcome these disadvantages, it is possible to develop anti-CMAS coatings capable of reacting with CMAS compounds before they have a detrimental effect on the integrity of the thermal barrier. In this study, we were particularly interested in anti-CMAS protective coatings based on yttria and pyrochlore systems, which were tested on industrial thermal barriers realized by EBPVD. Moreover, the processes we have developed, based on the sol-gel path, allow us, because of their ease of implementation, to envisage promising prospects in terms of repair of damaged thermal barriers. Indeed, given the high cost of manufacturing parts, the blades should be repaired several times before being discarded. In this work, a shaping process has been evaluated in this direction. This is electrophoretic deposition which is a technique allowing to deposit on complex parts. The objective of these investigations was therefore twofold: firstly to create new thermal barrier systems with anti-CMAS properties by electrophoretic deposition and then to repair the damaged EBPVD thermal barriers and to deposit an anti-CMAS protective layer by this same process. This "process" aspect will be discussed at the end of this work.

Les superalliages base nickel sont couramment utilisés dans les parties chaudes des turbines aéronautiques et de production d’énergie. Les températures employées, supérieures à 900°C, nécessitent de concevoir des revêtements protecteurs pour lutter contre les phénomènes d’oxydation. Les revêtements couramment utilisés, composés pour la plupart de la phase β-NiAl, permettent de retarder les phénomènes de dégradation en développant une couche d’alumine. Dans les sections les plus chaudes, une barrière thermique composée de céramique, associée à un système de refroidissement interne complètent le dispositif de protection en permettant d’abaisser la température effective au niveau du substrat métallique.Ces revêtements sont cependant onéreux et utilisent de nombreux produits polluants. Les travaux de cette thèse, qui s’inscrivent dans le cadre du projet européen Particoat, se proposent d’élaborer un système barrière thermique en une seule étape reposant sur l’application d’une barbotine à base aqueuse comprenant des microparticules d’aluminium, suivi d’un traitement thermique approprié. L’aluminium contenu dans les sphères devient liquide puis réagit avec le substrat pour former une couche d’intermétallique riche en aluminium par diffusion à l’état solide. Simultanément les coquilles des sphères s’oxydent pour former une structure mousse en surface du substrat qui va conférer au système son isolation thermique. La cohésion des deux parties est assurée par l’oxyde thermique qui se forme à la surface du revêtement inter métallique. Les mécanismes mis en jeu lors des différentes étapes, ont été étudiés sur un substrat modèle, le nickel, ainsi que sur trois superalliages industriels (René N5, PWA 1483 et CM-247). Les revêtements ainsi élaborés ont été testés en condition d’oxydation isotherme et cyclique entre 900 et1100°c pour le nickel et entre 1000 et 1100°C pour les superalliages revêtus. L’ensemble montre une bonne résistance du système barrière thermique élaboré par barbotine. / Nickel superalloys are commonly used in the high temperature sections of aero- and land-based turbines blades. Protection of these materials by coatings is required to improve their resistance to oxidation beyond 900°C. The conventional process consists of a β-NiAl, which allows to form a protective alumina scale with alow oxidation kinetic. In the hottest parts of the turbine, a ceramic is used as a thermal barrier coating in addition to an internal cooling system in order to diminish the temperature seen at the metallic substrate surface. However, these existing methods are expensive, long and pollutant. Thus, this PhD thesis aims at producing a new thermal barrier system in one step, in the frame of the European project Particoat. Its concept is to apply on the substrate an aqueous slurry containing aluminum microparticles. Then, during an appropriate heat treatment the metallic particles sinter and oxidize completely resulting in a quasi-foam structure made of alumina hollow spheres (TBC). Simultaneously, the diffusion of the Al into the substrate creates a bond coat below the TBC. This coating formation is studied on model alloy (pure nickel) and on three different superalloys (René N5, PWA-1483 and CM-247). The pure nickel coated system is tested during isothermal and cyclic oxidation between 900°C and 1100°C whereas the degradation of the superalloys is realized upon cyclic oxidation at 1000°C and 1100°C. The overall results show a good resistance of this new thermal barrier system, enlightened by an industrial aluminide coatings comparison.

A oxidação cíclica é um fenômeno que pode trazer problemas a diversas indústrias e, apesar de estudada em grande medida para materiais de alto desempenho, como superligas, pesquisas em materiais menos nobres são incipientes. Essa tese teve como objetivo investigar as propriedades de oxidação cíclica de materiais ferrosos de baixo custo e compará-las com as do aço inoxidável fundido ASTM A 297 grau HH modificado. A motivação surgiu de uma análise de falha de componente feito com aço HH e da possibilidade de pesquisar materiais com melhor relação custo-benefício em aplicações onde a principal solicitação seja a de resistência à oxidação cíclica. Seis ligas ferrosas com teores de cromo e níquel menores que o do aço HH, ou sem esses elementos, compuseram o estudo. Nestas ligas, os elementos silício e alumínio (1 liga) foram utilizados como alternativa para resistir à oxidação. As composições das ligas (% em peso) foram aproximadamente Fe-15Al-1,1C, Fe-14,5Si-4Cr-0,75C, Fe-5Si-5Cr-V-C, Fe-5Si-5Cr-4Ni-Nb-C, Fe-17Mn-5Si-10Cr-4Ni-V-C e Fe-12Mn-5Si-10Cr-4Ni-Nb-C, além do aço HH modificado (HH-mod). Foram realizados ensaios de oxidação cíclica nas temperaturas de 800, 900 e 1000 ºC e ensaios de dureza, tração e impacto. As ligas mostraram fragilidade, com exceção das ligas com alto teor de manganês que superaram o aço HH-mod em tenacidade. Em oxidação cíclica, as ligas apresentaram boa resistência, com taxas de variação de massa pequenas ou moderadas, e quando houve destacamento, este foi menor que o apresentado pelo aço HH-mod. Camadas oxidadas foram caracterizadas por técnicas de microscopia eletrônica de varredura (MEV), espectroscopia por dispersão de energia de raios-X (EDX) e difração de raios-X (DRX). Foi possível verificar a formação de óxidos protetores de Si, Cr ou Al, mas também de Fe, Cu e principalmente Mn. Por fim, a determinação das cinéticas de ganho de massa e destacamento mostrou que apesar de algumas ligas apresentarem kp maiores que os do aço HH-mod, todas sofreram menores destacamentos, o que ocorreu para o aço HH-mod nas três temperaturas, devido à diferença entre coeficientes de expansão térmica da matriz austenítica e dos óxidos. Dentre as demais ligas, Fe-15Al-1,1C e Fe-5Si-5Cr-4Ni-Nb-C não sofreram destacamentos e apresentaram baixo ganho de massa, devido às finas camadas de óxido e assim apresentando os melhores resultados. / The cyclic oxidation phenomenon can cause problems to several industries. Although studied in high performance materials, as superalloys, researches on less noble materials are incipient. The aim of this thesis was investigate the cyclic oxidation properties of low cost iron-based alloys and compare them with a cast stainless steel ASTM A 297 HH modified grade. The motivation was a failure analysis on a component made of HH and the possibility of research materials with a better cost-benefit ratio for applications where the main solicitation is the cyclic oxidation resistance. Six alloys with less chromium and nickel amount than HH steel, or without these elements, constituted the study. In these alloys, silicon and aluminum (1 alloy) were used to improve the oxidation resistance. The alloy compositions (weight %) were nearly Fe-15Al-1,1C, Fe-14,5Si-4Cr-0,75C, Fe-5Si-5Cr-V-C, Fe-5Si-5Cr-4Ni-Nb-C, Fe-17Mn-5Si-10Cr-4Ni-V-C and Fe-12Mn-5Si-10Cr-4Ni-Nb-C, and the HH steel modified (HH-mod). Cyclic oxidation tests were performed at 800, 900 and 1000 ºC and also hardness, impact and tensile tests. The alloys studied presented brittleness, and only the high Mn alloys had better mechanical properties than HH-mod steel. The alloys presented good results on cyclic oxidation, with low or moderate oxidation rates and when suffering spallation, it was less than HH-mod steel. Oxidized scales were characterized by scanning electron microscope (SEM), energy dispersive spectroscopy (EDS) and X-Ray diffraction (XRD). The formation of protective oxide of Si, Cr or Al was noticed, but also Fe, Cu and Mn oxides were found. Finally, the mass gain and spallation kinetics was determined, and spite the fact of some alloys having higher kp values than HH-mod, no alloys suffered more spallation than HH steel. The austenitic matrix was considered the responsible of this behavior in all temperatures, due to the high thermal expansion coefficient compared with oxides. The better results were found to Fe-15Al-1,1C and Fe-5Si-5Cr-4Ni-Nb-C alloy, with low mass gain and without spalling, on account of the thin oxide scales formed.

[pt] O desenvolvimento e a utilização de aços rápidos para a produção da casca externa de cilindros destinados à laminação de tiras a quente tiveram início no começo dos anos 90. A introdução deste material melhorou, significativamente, a resistência ao desgaste do cilindro, a qualidade da tira laminada e a duração da campanha de laminação. Representou, desta forma, o maior avanço tecnológico recentemente obtido no campo da laminação a quente. Entretanto, foi observado que o desprendimento da camada de óxido nestes aços possuía características diferentes daquelas obtidas nos cilindros de laminação convencionais. Este fenômeno foi atribuído ao processo de oxidação dos aços rápidos, que é cerca de quatro vezes maior do que o das ligas anteriormente utilizadas. Para que todo o potencial dos cilindros de laminação a quente, fabricados com este material, seja alcançado, torna-se necessário, portanto, o estudo da oxidação de aços rápidos. A presente tese estudou a oxidação de quatro composições químicas de aços rápidos. Foram realizados ensaios de termogravimetria em atmosfera de ar seco e úmido (12,5% H2O) assim como ciclagem térmica com resfriamento em água. Um aparelho de produção e controle de umidade e um mecanismo de ciclagem térmica foram construídos para este trabalho. As amostras oxidadas foram analisadas por difração de Raios - X, microscopia eletrônica de varredura e espectroscopia de dispersão de energia. A discussão dos resultados avaliou o efeito da composição química, da umidade e da ciclagem térmica no comportamento dos aços rápidos estudados quanto à oxidação. Como conclusões, verificou-se que o teor de cromo possui influência no ganho final de massa, que um teor elevado de molibdênio pode promover oxidação catastrófica em atmosfera de ar seco e que a variação do teor de tungstênio utilizada não influenciou o comportamento de oxidação. Foi verificado também que a presença de 12,5 % de H2O influenciou significativamente as características de oxidação e que a oxidação em condição de ciclagem térmica promoveu a formação de uma fina camada de óxidos ricos em vanádio na região externa da camada de óxido das amostras estudadas. / [en] Development and use of high-speed steel for manufacturing the roll outer shell of hot strip mills have started in the early 1990s. The introduction of this material has improved, significantly, the roll wear resistance, the surface quality of rolled products and the length of rolling campaign. It has represented, therefore, the major technological breakthrough recently introduced in the hot rolling field. However, it was observed that the oxide layer spalling of these steels had different behavior in comparison with that of conventional rolls. This phenomenon has been attributed to the high-speed steel oxidation, which is about four times higher than the alloys previously used. In order to achieve the full potential of high-speed rolls for hot strip mills, it is necessary, therefore, to study the oxidation behavior of this material. The present thesis studied the oxidation of four different chemical compositions of high-speed steels. Corrosion tests were carried out in a thermobalance under dry and moist (12.5 % H2O) environments. Oxidation under thermal cyclic conditions of specimens cooled in water was also carried out. A cyclic oxidation apparatus and an equipment for humidity production and control were constructed for this work. The corroded samples were examined by X - Ray diffraction, scanning electron microscopy and energy dispersive micro-analysis. The discussion of the results evaluated the effects of humidity, thermal cycling and chemical composition on the oxidation behavior of these high-speed steels. As conclusions, it was verified that the chromium content has influence on the final mass gain, the elevated molybdenum content can produce catastrophic oxidation under dry air environment and that the tungsten content variation did not influence the oxidation behavior. It was also verified that the presence of humidity had a significant effect on the oxidation behavior and that the cyclic oxidation promoted the formation of a thin layer composed of oxides rich in vanadium at the outer region of the scale.

A oxidação cíclica é um fenômeno que pode trazer problemas a diversas indústrias e, apesar de estudada em grande medida para materiais de alto desempenho, como superligas, pesquisas em materiais menos nobres são incipientes. Essa tese teve como objetivo investigar as propriedades de oxidação cíclica de materiais ferrosos de baixo custo e compará-las com as do aço inoxidável fundido ASTM A 297 grau HH modificado. A motivação surgiu de uma análise de falha de componente feito com aço HH e da possibilidade de pesquisar materiais com melhor relação custo-benefício em aplicações onde a principal solicitação seja a de resistência à oxidação cíclica. Seis ligas ferrosas com teores de cromo e níquel menores que o do aço HH, ou sem esses elementos, compuseram o estudo. Nestas ligas, os elementos silício e alumínio (1 liga) foram utilizados como alternativa para resistir à oxidação. As composições das ligas (% em peso) foram aproximadamente Fe-15Al-1,1C, Fe-14,5Si-4Cr-0,75C, Fe-5Si-5Cr-V-C, Fe-5Si-5Cr-4Ni-Nb-C, Fe-17Mn-5Si-10Cr-4Ni-V-C e Fe-12Mn-5Si-10Cr-4Ni-Nb-C, além do aço HH modificado (HH-mod). Foram realizados ensaios de oxidação cíclica nas temperaturas de 800, 900 e 1000 ºC e ensaios de dureza, tração e impacto. As ligas mostraram fragilidade, com exceção das ligas com alto teor de manganês que superaram o aço HH-mod em tenacidade. Em oxidação cíclica, as ligas apresentaram boa resistência, com taxas de variação de massa pequenas ou moderadas, e quando houve destacamento, este foi menor que o apresentado pelo aço HH-mod. Camadas oxidadas foram caracterizadas por técnicas de microscopia eletrônica de varredura (MEV), espectroscopia por dispersão de energia de raios-X (EDX) e difração de raios-X (DRX). Foi possível verificar a formação de óxidos protetores de Si, Cr ou Al, mas também de Fe, Cu e principalmente Mn. Por fim, a determinação das cinéticas de ganho de massa e destacamento mostrou que apesar de algumas ligas apresentarem kp maiores que os do aço HH-mod, todas sofreram menores destacamentos, o que ocorreu para o aço HH-mod nas três temperaturas, devido à diferença entre coeficientes de expansão térmica da matriz austenítica e dos óxidos. Dentre as demais ligas, Fe-15Al-1,1C e Fe-5Si-5Cr-4Ni-Nb-C não sofreram destacamentos e apresentaram baixo ganho de massa, devido às finas camadas de óxido e assim apresentando os melhores resultados. / The cyclic oxidation phenomenon can cause problems to several industries. Although studied in high performance materials, as superalloys, researches on less noble materials are incipient. The aim of this thesis was investigate the cyclic oxidation properties of low cost iron-based alloys and compare them with a cast stainless steel ASTM A 297 HH modified grade. The motivation was a failure analysis on a component made of HH and the possibility of research materials with a better cost-benefit ratio for applications where the main solicitation is the cyclic oxidation resistance. Six alloys with less chromium and nickel amount than HH steel, or without these elements, constituted the study. In these alloys, silicon and aluminum (1 alloy) were used to improve the oxidation resistance. The alloy compositions (weight %) were nearly Fe-15Al-1,1C, Fe-14,5Si-4Cr-0,75C, Fe-5Si-5Cr-V-C, Fe-5Si-5Cr-4Ni-Nb-C, Fe-17Mn-5Si-10Cr-4Ni-V-C and Fe-12Mn-5Si-10Cr-4Ni-Nb-C, and the HH steel modified (HH-mod). Cyclic oxidation tests were performed at 800, 900 and 1000 ºC and also hardness, impact and tensile tests. The alloys studied presented brittleness, and only the high Mn alloys had better mechanical properties than HH-mod steel. The alloys presented good results on cyclic oxidation, with low or moderate oxidation rates and when suffering spallation, it was less than HH-mod steel. Oxidized scales were characterized by scanning electron microscope (SEM), energy dispersive spectroscopy (EDS) and X-Ray diffraction (XRD). The formation of protective oxide of Si, Cr or Al was noticed, but also Fe, Cu and Mn oxides were found. Finally, the mass gain and spallation kinetics was determined, and spite the fact of some alloys having higher kp values than HH-mod, no alloys suffered more spallation than HH steel. The austenitic matrix was considered the responsible of this behavior in all temperatures, due to the high thermal expansion coefficient compared with oxides. The better results were found to Fe-15Al-1,1C and Fe-5Si-5Cr-4Ni-Nb-C alloy, with low mass gain and without spalling, on account of the thin oxide scales formed.

Les aciers ferritiques à faible teneur en chrome tel que le T/P91 sont largement utilisés dans les centrales de productions d’électricité pour leurs bonnes propriétés mécaniques et leur faible coefficient d’expansion thermique. Cependant, la demande croissante en énergie alliée à la nécessité de réduire les émissions de gaz à effet de serre, conduisent à envisager l’augmentation des conditions d’utilisation (température et pression) de ces matériaux. Des études ont montré qu’en modifiant la température de fonctionnement et la pression de vapeur d’eau de 538°C/18.5 MPa à 650°C/30 MPa, le rendement des centrales thermiques progressait d’environ 8%. Se pose alors la question de la tenue à la corrosion à haute température des aciers à 9% de chrome. Au cours de ces travaux, le comportement d’un acier ferritique/ martensitique à 9% de chrome a été étudié à 650°C sous air sec et sous vapeur d’eau de matière isotherme et en conditions de cyclage thermique. La prise de masse des échantillons renseigne sur la cinétique de la réaction d’oxydation et l’adhérence des couches d’oxydes formées. Les produits de corrosion ont été caractérisés par plusieurs techniques d’analyses dans l’optique de clairement identifiés les oxydes en présences et leurs mécanismes de formation. Des oxydes mixtes de fer et de chrome (Cr,Fe)2O3 sont dans un premier temps formés et assurent s’avèrent être temporairement protecteur. Pour des longs temps d’oxydation ou des températures supérieures à 650°C, la magnétite Fe3O4 et l’hématite Fe2O3 sont les principaux oxydes formés, montrant ainsi l’inadéquation des nuances à faible teneur en chrome pour une utilisation dans des conditions aussi drastiques. Dans l’optique d’augmenter la résistance à la corrosion à haute température de cet alliage, diverses solutions ont été envisagées tel que l’aluminisation par cémentation en caisse, les revêtements d’oxydes de terre rare par MOCVD, ou encore l’ajout d’éléments d’addition. Ces solutions ont été également testées à 650°C sous air sec et sous vapeur d’eau. / The improvement of high temperature oxidation resistance of low chromium content steels, such as T/P91, is of great interest in regards with their application in thermal power generating plants. Indeed, they possess good creep properties, and low thermal expansion coefficient. Important needs in energy together with environmental issues place power generation plants under constraints which lead to develop high efficiency systems. A usual way to increase the efficiency consists in increasing temperature and pressure parameters of the power generating plant. Studies has shown that the total efficiency of a plant increases by nearly 8 % when changing the steam parameters from 538°C/18.5 MPa to 650°C/30 MPa. Then, the problem of corrosion resistance of 9% chromium steel in those conditions is asked. In this work, the behavior of a ferritic / martensitic 9% chromium steel has been studied at 650°C in dry air and in water vapor containing environment in both isothermal and thermal cyclic conditions. The weight gain of samples provides information on the kinetics of the oxidation reaction and the adhesion of formed oxide scale. Corrosion products were characterized by several analytical techniques in order to identify oxides with accuracy and to understand their formation mechanisms. Mixed iron and chromium oxides (Cr, Fe) 2O3 are initially formed and provide temporary protection to the substrate. For long time exposure or temperatures above 650°C, magnetite, Fe3O4 and hematite Fe2O3 are the main oxides formed, highlighting the fact that low chromium steel are inappropriate for applications in such drastic conditions. In order to increase the high temperature corrosion resistance of this alloy, various solutions have been proposed as aluminizing by pack cementation, reactive element oxides coatings of by MOCVD, or addition of alloying elements in the steel composition. These solutions were then tested at 650 ° C in dry air and in water vapor environments.

Les principaux objectifs de ces travaux de thèse sont d'une part d'optimiser le protocole d'élaboration des barrières thermiques (BT) issues de la voie sol-gel et d'autre part de caractériser l'adhérence de ces barrières thermiques mais aussi de proposer des pistes en vue d'augmenter la durée de vie de celles-ci. Tout d'abord, une première étude a porté sur le choix et la validation d'un nouvel agent dispersant pour optimiser la formulation du sol chargé permettant la mise en forme des barrières thermiques. Ainsi, ce changement de dispersant a généré une microstructure conduisant à une augmentation significative de la durée de vie du système en oxydation cyclique mais a aussi permis de simplifier le protocole d'élaboration puisque l'étape de colmatage, jusqu'alors nécessaire, a été supprimée. L'étude paramétrique de la microstructure surfacique des barrières thermiques a montré que le réseau de microfissures formé initialement restait stable en fonction du vieillissement avec la création d'un sous-réseau microfissuré. Pour comprendre les mécanismes d'endommagement des barrières thermiques sol-gel et les confronter à ceux des barrières thermiques industrielles EB-PVD, la méthode d'indentation interfaciale a été retenue pour sonder l'interface revêtement/substrat. Ainsi des valeurs de ténacités apparentes ont pu être déterminées afin de comparer les adhérences des BTSG et des BTEB-PVD. A partir de ces résultats, des modèles phénoménologiques d'endommagement ont été imaginés. Pour les BTEB-PVD, l'initiation et la propagation de fissures restent localisées à l'interface barrière thermique/sous-couche de liaison, d'un coté ou de l'autre de l'oxyde de croissance selon les conditions, alors que pour les BTSG, l'endommagement est induit par la libération d'énergie élastique stockée dans le système qui augmente en fonction du vieillissement. / The main objectives of this PhD are first to improve and optimise the elaboration protocol of thermal barrier coatings (TBC) manufactured by the sol-gel route and then to characterise their adhesion and investigate the possibility to enhance their lifetime. A preliminary study is focused on the selection and validation of a new dispersing agent to optimise the composite sol formulation before shaping TBC. Indeed, the new dispersant induced a microstructure allowing to significantly increase the cyclic oxidation lifetime of the system but also to simplify the elaboration process as the reinforcement step was suppressed. The parametric study of TBC surface microstructure proved that the initial micro-cracks network remained stable during ageing including the formation of a crack sub-network. To understand the damage mechanisms of sol-gel TBC and to compare them to those corresponding to industrial EB-PVD TBC, the method of interfacial indentation was developed to investigate the subtrate/top-coat interface. The apparent toughness values were determined to compare both BTSG and BTEB-PVD adhesions. From these results, phenomenological models for damage mechanisms were proposed. For BTEB-PVD, crack initiation and propagation are located at the top-coat/bond-coat interface, either on one side or the other side of the thermally grown oxide (TGO) depending of the conditions. For BTSG, the damage is a consequence of the release of the elastic strain energy stored in the system, increasing with the ageing temperature.

Ce travail s’inscrit dans un cadre de recherche qui a pour objectif essentiel l’étude de l’influence de la vapeur d’eau sur l’oxydation à haute température d’un alliage formeur de Cr2O3 à base de nickel. L’alliage étudié pour cette étude est le SY 625. L’originalité de cette étude repose sur l’utilisation d’un montage expérimental, mis en oeuvre au laboratoire. Ce montage appelé « montage vapeur d’eau » permet de réaliser l’oxydation du SY 625 à haute température (900-1100°C) en présence de vapeur d’eau (7,5 et 33% de vapeur d’eau) avec différents gaz vecteurs (oxygène, air, argon et azote) en conditions isotherme ou cyclique. Les résultats cinétiques obtenus sous air, ne montrent pas de différences notables que l’oxydation soit réalisée en conditions sèche ou humide (quelque soit le taux de vapeur d’eau). Les résultats n’ont pas montré de breakaway pour les durées d’oxydation allant jusqu’à 48 heures. Ceci est attribué au fait qu’il n’y a pas formation d’oxydes de fer sachant que l’alliage contient seulement 0,23% en masse de fer. Les résultats de DRX montrent la formation des mêmes phases quel-que-soit le gaz vecteur utilisé (en atmosphère sèche ou humide). A 900 et 1000°C, l’oxyde Cr2O3 est détecté ainsi que deux composés intermétalliques : Ni3Mo et NbNi4. En revanche à 1100°C, l’oxyde Cr2O3 est toujours présent mais les composés intermétalliques sont oxydés pour donner un oxyde mixte CrNbO4. L’oxydation du molybdène au dessus de 1000°C conduit à la formation de MoO3 qui est un oxyde volatil. Les analyses morphologiques, ont montré la présence de couches de chromine plus plastiques avec une porosité répartie sur toute l’épaisseur de la couche pour les essais réalisés en présence de vapeur d’eau. Les couches d’oxyde sont alors plus adhérentes. Ceci a été confirmé par des essais d’oxydation en conditions cycliques, qui ont montré notamment à 1100°C, une meilleure tenue mécanique de la couche d’oxyde en présence de vapeur d’eau. Les tests d’oxydation en présence d’un marquage à l’or a aussi permis de mettre en évidence un mécanisme d’oxydation mixte pour les oxydations réalisées en atmosphères riche en oxygène que l’on soit sous atmosphère sèche ou humide. En revanche, le marquage à l’or a montré la présence d’un mécanisme d’oxydation interne pour les atmosphères pauvres en oxygène, avec des couches d’oxydes présentant une adhérence parfaite. Le fait d’ajouter de la vapeur d’eau à ces atmosphères pauvres en oxygène, entraine la réapparition d’un mécanisme de diffusion mixte. / This work is a part of a research project which has for essential objective the study of water vapor influence in high temperature oxidation for a chromia forming nickel base alloy. Alloy studied for this study is the SY 625. Originality of this study is based on an experimental assembly use, create in the laboratory. This assembly called “water vapor assembly” is used for realized SY 625 high temperature oxidation (900-1100°C) in presence of water vapor (7,5 and 33 vol. % water vapor) with various carriers gas (oxygen, air, argon and nitrogen) in isothermal and cyclic conditions. The kinetic results obtained under air, do not show considerable differences that the oxidation is realized in dry or wet conditions (with the various water vapor rate). The results do not show breakaway for the oxidation durations going to 48 hours. This is attributed to the fact that there is no formation of oxides iron knowing that the alloy contains only 0,23 mass % of iron. The XRD results show the formation of the same phases which is the carrier gas used (in dry or wet atmosphere). At 900 and 1000°C, the Cr2O3oxide is detected with two intermetallic compounds : Ni3Mo and NbNi4. On the other hand at 1100°C, the oxide Cr2O3 is always present but the intermetallic compounds are oxidized to give a mixed oxide CrNbO4. The oxidation of the molybdenum above 1000°C leads to the formation of MoO3 which is a volatile oxide. The morphological analyses, showed the presence of more plastic chromia layers with a distributed porosity on all the thickness of the layer for the test realized in water vapor presence. The oxide layers are then more adherents. This was confirmed by oxidation test in cyclic conditions, which showed in particular at 1100°C, a better mechanical behavior of oxide layer in water vapor presence. The oxidation tests with gold marker experiments are also showed a mixed oxidation mechanism for the oxidations realized in rich oxygen atmospheres under dry or wet atmosphere. On the other hand, gold marker experiments showed the presence of a internal oxidation mechanism for poor oxygen atmospheres, with oxides layers showing a perfect adhesion. The fact of adding water vapor to these poor oxygen atmospheres, lead to the reappearance of a mixed diffusion mechanism.

Les systèmes barrière thermique actuels connaissent une importante dispersion de durées de vie liée principalement aux ondulations de surface du revêtement métallique β-(Ni,Pt)Al provoquant l’écaillage du dépôt céramique. Les revêtements γ-γ’ riches en platine sont étudiés en tant qu’alternative au système actuel. Ce travail de thèse s’est intéressé à l’élaboration des revêtements γ-γ’ riches en platine sur un superalliage à base de nickel, l’AM1 à partir de procédés conventionnels : dépôt électrolytique de platine et aluminisation courte. Les mécanismes de dégradation par oxydation cyclique à 1100°C ont été étudiés sur des systèmes revêtement/AM1 et sur des systèmes barrière thermique. Pour comparaison, trois types de revêtement ont été élaborés : γ-γ’ Pt seul, γ-γ’ Pt+Al et β-(Ni,Pt)Al. Ces essais ont mis en évidence une meilleure tenue à l’oxydation cyclique des systèmes revêtus γ-γ’ Pt+Al comparée aux deux autres systèmes revêtus. L’importance de l’ajout d’aluminium dès l’élaboration sur la tenue à l’oxydation cyclique a été soulignée. La modélisation p-kp a mis en avant une augmentation de la proportion d’écaillage au cours du temps du fait de la dégradation de l’interface métal/oxyde et une augmentation du kp du fait de la formation d’un oxyde à croissance plus rapide. Outre l’oxydation, les phénomènes d’interdiffusion lors des tous premiers instants à haute température ont été étudiés à partir de matériaux modèles (Ni13Al et Ni11Al10Cr) et de revêtements de Pt et/ou de Pt-Ir. Ces essais ont mis en avant la rapide formation de la phase α-NiPtAl, les transformations de phases et les chemins de diffusion à 1100°C dans les systèmes Ni-Al-Pt et Ni-Al-Cr-Pt. L’effet du chrome et de l’iridium sur les cinétiques de diffusion a été évalué. La modélisation de l’interdiffusion a mis en évidence les interactions chimiques entre les espèces et une sursaturation en lacunes dans la zone d’interdiffusion prouvant que l’effet Kirkendall est responsable de la formation des pores. / TBC systems currently used in aircraft engines with a Pt-modified aluminide coating β-(Ni,Pt)Al show an important lifetime dispersion due to the surface undulations of the bond-coating. This phenomenon called rumpling leads to the ceramic scale spallation and is the most common degradation mechanism. Pt-rich γ-γ’ bond-coatings have been extensively studied for their corrosion and oxidation resistance, and as a lower cost alternative to β-(Ni,Pt)Al bond-coatings. The aim of this work was to fabricate Pt-rich γ-γ’ bond-coatings on a first generation Ni-based superalloy, the AM1. Conventional processes were used as a platinum electroplating and a short aluminizing step. The failure mechanisms occurring by cyclic oxidation at 1100°C were studied on coating/superalloy systems and on TBC systems. Three kinds of coatings were fabricated: Pt-only γ-γ’, Pt+Al γ-γ’ and β-(Ni,Pt)Al. These tests highlighted the best oxidation resistance for the Pt+Al γ-γ’/AM1 systems when compared with the two other systems. Al addition during the coating fabrication is necessary to improve the lifetime. The p-kp modeling results pointed out that the oxide scale spalling probability p increases due to the metal/oxide interface degradation with time. If the spallation increases, a breakaway locally occurs with the formation of a fast-growing oxide explaining the kp progression. The interdiffusion phenomena were also investigated during the first times at high temperature from model alloys (Ni13Al and Ni11Al10Cr) and Pt and/or Pt-Ir coatings. These investigations emphasized the rapid formation of the α-NiPtAl phase, the phase transformations and diffusion paths at 1100°C in the ternary Ni-Al-Pt and quaternary Ni-Al-Cr-Pt systems. Chromium and iridium effect was evaluated on the diffusion kinetics. Interdiffusion modeling highlighted the chemical interactions between the species and a vacancy supersaturation in the interdiffusion zone proving that Kirkendall effect is responsible for void formation.