This work compares the oxidation behaviour of CoNiCrAlY coatings manufactured by the HVOF, APS and CGDS processes when submitted to temperatures of 1000°C and 1100°C. The as-sprayed coating microstructural features were characterised using SEM and XRD analysis before being subjected to isothermal heat treatments in an air furnace. Oxide scale composition was determined using XRD, SEM and EDS analysis while the oxide growth rates were obtained using mass gain measurements. The as-sprayed HVOF and CGDS coatings exhibit similar microstructures while the APS samples have a significantly higher porosity and oxide content levels. Results from the oxidation experiments indicated that the oxide growth rate of HVOF and CGDS were lower than that of the APS samples. The results also indicated that samples oxidised at 1100°C have a lower oxide growth rate than those oxidised at 1000°C. Analysis of the oxidation process up to 100 hours indicates that the formation of dense α-Al2O3 is more favourable at 1100°C while a transition alumina, θ-Al2O3 is more favourable at 1000°C. Furthermore, the surface profile of the samples oxidised at 1100°C were more uniform and free of protrusions.

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