The interfacial bonding at protective coatings and Zr alloy substrates could have a significant effect on the corrosion behaviors of the coatings. In this work, FeCrAl-Zr couples were fabricated at 900 °C by spark plasma sintering (SPS), and the interfacial bonding of the couples was modified through the addition of Si and/or thermal diffusion at 1100 °C–1300 °C. Uphill diffusion of silicon occurred during SPS. The corrosion resistance of the couples in 400 °C/10.3 MPa steam, and the effects of the interfacial bonding characteristics were studied. Due to the presence of ZrSi₂ in the interfacial layer, the interfacial bonding of the FeCrAl/Si-Zr couple had a better corrosion resistance than that of the FeCrAl-Zr couple, withstanding 14 days of corrosion in steam compared to 7 days for the FeCrAl-Zr couple. The results also suggested that bimetallic effect could accelerate the oxidation of Zr alloy at the interface of the couples, and galvanic corrosion significantly contributed to the serious corrosion of the interface of the diffusion bonded couples with thermal diffusion. The influence of oxide growth stress around interface on the bonding lifetime of the couples was also discussed.

保护涂层和Zr合金基材之间的界面结合可能对涂层的腐蚀行为产生重大影响。在这项工作中，通过火花等离子体烧结（SPS）在900°C下制造了FeCrAl-Zr对，并通过添加Si和/或在1100°C–1300°C下进行热扩散来修改了这些对的界面键合。在SPS期间发生了硅的向上扩散。研究了在400°C / 10.3 MPa的蒸汽中，偶对的耐蚀性以及界面键合特性的影响。由于存在ZrSi ₂在界面层中，FeCrAl / Si-Zr对的界面结合性比FeCrAl-Zr对具有更好的耐腐蚀性，在蒸汽中的腐蚀时间为14天，而FeCrAl-Zr对则为7天。结果还表明，双金属效应可以加速Zr合金在偶合界面处的氧化，并且电化腐蚀显着地促进了扩散键合偶合界面在热扩散下的严重腐蚀。还讨论了氧化物在界面周围的生长应力对夫妇的键合寿命的影响。