Molybdenum-titanium-zirconium (TZM) alloy, renowned for its high refractory properties, has limited applications in open atmospheres because of its low resistance to oxidation at elevated temperatures. In this study, Ni-Al2O3 cold spray coating was employed to create a protective layer on the TZM to protect against high-temperature oxidation. The microstructure, microhardness, and oxidation performance of the Ni-based MMC coating were investigated at various temperatures up to 1000 °C. The MMC coating's microstructure consisted of Al2O3 particles randomly distributed within the nickel matrix, resulting from the CS coating, which is a solid-state deposition method. In the oxidation tests of TZM at temperatures of 750 and 1000 °C, it was observed that there was a significant mass loss because of the generation and evaporation of the MoO3 phase. It was determined that the Ni-based MMC coating on TZM significantly reduced mass loss by preventing molybdenum from coming into contact with oxygen. Following the 1000 °C oxidation test, the XRD examination revealed the presence of MoO2 and MoO3 phases on the surfaces of TZM, while NiO and NiMoO4 phases were identified on the surfaces of the MMC coating. It was determined that the NiMoO4 phase formed at the end of the MoO3 vapor on the TZM side surfaces, while the NiO phases developed in the MMC coating layer through a chemical reaction.
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