SUMMARY
Electrolytic codeposition is a promising alternative low-cost process for fabricating MCrAlY coatings. In this process, CrAlY particles are codeposited with the (Ni,Co) to form an (Ni,Co)-CrAlY composite coating, which is subsequently heat treated at elevated temperatures to be transformed to the MCrAlY coating containing phases of β-NiAl, γ-(Ni,Co), etc. Two types of CrAlY-based particles (made by ball milling and gas atomization) were employed. The effects of several key processing parameters, such as current density, particle loading, and particle size/shape density, on the CrAlY particle incorporation in the electrodeposited (Ni,Co)-CrAlY coatings were studied. For the ball-milled CrAlY powder, an increase in current density led to a decrease in particle incorporation, whereas for the gas-atomized CrAlY powder the current density showed a negligible influence on particle incorporation. The relationship of particle incorporation and particle loading followed t