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Zinc-nickel ?-phase silicate and copper-nickel silicate corrosion resistant coatings have been prepared via electrochemical methods to improve currently available corrosion resistant materials in the oil and gas industry. A layered silicate, montmorillonite, has been incorporated into the coatings for increased corrosion protection. For the zinc nickel silicate coatings, optimal plating conditions were determined to be a working pH range of 9.3 -9.5 with a borate based electrolyte solution, resulting in more uniform deposits and better corrosion protection of the basis metal as compared to acidic conditions. Quality, strongly adhering deposits were obtained quickly with strong, even overall coverage of the metal substrate. The corrosion current of the zinc-nickel-silicate coating is Icorr = 3.33E-6 for a borate based bath as compared to a zinc-nickel bath without silicate incorporation (Icorr = 3.52E-5). Step potential and direct potential methods were examined, showing a morphological advantage to step potential deposition. The effect of borate addition was examined in relation to zinc, nickel and zinc-nickel alloy deposition. Borate was found to affect the onset of hydrogen evolution and was examined for absorption onto the electrode surface. For copper-nickel silicate coatings, optimal conditions were determined to be a citrate based electrolytic bath, with pH = 6. The solutions were stable over time and strong adhering, compact particle deposits were obtained. The corrosion current of the copper-nickel-silicate coatings is Icorr = 3.86E-6 (copper-nickel coatings without silicate, Icorr = 1.78E-4). The large decrease in the corrosion current as the silicate is incorporated into the coating demonstrates the increase in corrosion resistance of the coatings with the incorporation of silicates.

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Afin d’accroitre le rendement des turbomachines les motoristes aéronautiques visent à développer de nouveaux matériaux réfractaires permettant d’augmenter les températures de service des parties les plus chaudes. Les travaux présentés dans ce mémoire s’inscrivent dans ce contexte et ont pour cadre le projet européen FP7-HYSOP dans lequel les alliages Nbss-Nb5Si3 sont à l’étude. Alors que d’un point de vue mécanique leurs propriétés sont compatibles avec leur industrialisation, leur résistance à l’oxydation dès les températures intermédiaires (800°C) constitue l’obstacle majeur à leur application. Deux voies sont suivies dans ce travail pour améliorer ce comportement. La première vise à évaluer l’effet d’un affinement de microstructure en synthétisant l’alliage Nbss-Nb5Si3 soit par la voie fusion, soit par métallurgie des poudres. Il a été montré que les microstructures les plus fines permettent de diminuer les cinétiques d’oxydations à 1100°C, et de s’affranchir des phénomènes d’oxydation catastrophique dont souffrent les alliages à microstructure grossière à 815°C. Des modèles diffusionnels gouvernant l’oxydation de ces matériaux ont pu être proposés. La seconde partie se focalise sur le développement de revêtements à base de siliciures, par la technique de cémentation activée en caisse, dont le caractère protecteur est assuré principalement par la formation d’une couche de silice (SiO2). Une série de tests d’oxydation/corrosion, représentative des conditions extrêmes régnant en sortie de chambre de combustion (isotherme ou cyclique, sous air, air + H2O, mélange silicaté CMAS), a permis d’évaluer et de hiérarchiser les performances des différents systèmes revêtus / Progress in the field of gas-Turbine engines for aircrafts is controlled by the availability of new structural materials able to withstand higher temperatures than nickel based superalloys. The present PhD work was conducted in this context, within the framework of the European FP7-HYSOP project, in which Nbss-Nb5Si3 alloys are studied. From a mechanical point of view, the physicochemical properties (room temperature fracture toughness and creep rate) are compatible with the targeted temperature (1300°C). However, starting from the intermediate temperatures (800°C), the oxidation resistance of those alloys is the major obstacle to their use. In this work, two ways are investigated to improve this behavior: The first one aims at studying the effect of a refinement of microstructure synthesizing the Nbss-Nb5Si3 alloy both by fusion method and powder metallurgy route. It was shown that refining the microstructure led to decrease the oxidation kinetics at 1100°C and suppressed the catastrophic breakaway oxidation (pesting) typical of the Nb-Si alloys with coarse microstructure at 815°C. Furthermore, diffusion models were proposed to describe oxidation kinetics both at 815°C and 1100°C. The second part of this study is devoted to the development of silica forming protective coatings. Diffusion silicide coatings were manufactured by the halide activated pack-Cementation method. The various conditions of oxidation/corrosion tests (isothermal or cyclic, in air, air containing water vapor, CMAS silicate melt) allowed assessing and ranking the performance of coated systems