Oxide Dispersion Strengthened Fe3Al-Based Alloy Tubes: Application Specific Development for the Power Generation Industry

A detailed and comprehensive research and development methodology is being prescribed to produce Oxide Dispersion Strengthened (ODS)-Fe{sub 3}Al thin walled tubes, using powder extrusion methodologies, for eventual use at operating temperatures of up to 1100% in the power generation industry. A particular ''in service application'' anomaly of Fe{sub 3}Al-based alloys is that the environmental resistance is maintained up to 1200 C, well beyond where such alloys retain sufficient mechanical strength. Grain boundary creep processes at such high temperatures are anticipated to be the dominant failure mechanism. Thus, the challenges of this program are manifold: (1) to produce thin walled ODS-Fe{sub 3}Al tubes, employing powder extrusion methodologies, with (2) adequate increased strength for service at operating temperatures, and (3) to mitigate creep failures by enhancing the as-processed grain size in ODS-Fe{sub 3}Al tubes. Our research progress till date has resulted in the successful batch production of typically 8 Ft. lengths of 1-3/8 inch diameter, 1/8 inch wall thickness, ODS-Fe{sub 3}Al tubes via a proprietary single step extrusion consolidation process. The process parameters for such consolidation methodologies have been prescribed and evaluated as being routinely reproducible. Such processing parameters (i.e., extrusion ratios, temperature, can design etc.) were particularly guided by the need to effect post-extrusion recrystallization and grain growth at a sufficiently low temperature, while still meeting the creep requirement at service temperatures. Static recrystallization studies show that elongated grains (with their long axis parallel to the extrusion axis), typically 200-2000 {micro}m in diameter, and several millimeters long can be obtained routinely, at 1200 C. The growth kinetics are affected by the interstitial impurity content in the powder batches. For example complete recrystallization, across the tube wall thickness, is observed for clean powders (PMWY-3) and consequently this powder batch exhibits the best creep performance. Prolonged exposures (about 700 hours) at 10 Ksi at 1000 C have been achieved till date. The high impurity content powder batches (PMWY-1 and PMWY-2) exhibit modest improvements in tensile and creep response behavior at 1000 C upon further selective heat-treatments intended to increase grain size

Optimization of High Temperature Hoop Creep Response in ODS-Fe3Al Tubes

Oxide dispersion strengthened (ODS) Fe3Al alloys are currently being developed for heat-exchanger tubes for eventual use at operating temperatures of up to 1100 C in the power generation industry. The development challenges include (a) efforts to produce thin walled ODS-Fe3Al tubes, employing powder extrusion methodologies, with (b) adequate increased strength for service at operating temperatures to (c) mitigate creep failures by enhancing the as-processed grain size. A detailed and comprehensive research and development methodology is prescribed to produce ODS-Fe3Al thin walled tubes. Current single step extrusion consolidation methodologies typically yield 8ft. lengths of 1-3/8 inch diameter, 1/8 inch wall thickness ODS-Fe3Al tubes. The process parameters for such consolidation methodologies have been prescribed and evaluated as being routinely reproducible. Recrystallization treatments at 1200 C produce elongated grains (with their long axis parallel to the extrusion axis), typically 200-2000 {micro}m in diameter, and several millimeters long. The dispersion distribution is unaltered on a micro scale by recrystallization, but the high aspect ratio grain shape typically obtained limits grain spacing and consequently the hoop creep response. Improving hoop creep in ODS-alloys requires an understanding and manipulating the factors that control grain alignment and recrystallization behavior. Current efforts are focused on examining the processing dependent longitudinal vs. transverse creep anisotropy, and exploring post-extrusion methods to improve hoop creep response in ODS-Fe3Al alloy tubes. In this report we examine the mechanisms of hoop creep failure and describe our efforts to improve creep performance via variations in thermal-mechanical treatments

Laser shock compression of copper monocrystals: Mechanisms for dislocation and void generation

Copper with two orientations ([001] and [134]) was subjected to high intensity laser (energy levels of 40-300 J; energy densities of 15-70 MJ/m$^2$ and durations below 10 ns). The defects created are characterized by transmission electron microscopy. An orientation-dependent threshold stress for twinning is observed. The results are rationalized in terms of a criterion in which slip and twinning are considered as competing mechanisms. A constitutive description is applied to the two orientations, incorporating both slip and twinning. The predictions are in agreement with experiments. The threshold stress for twinning in the [001] orientation is 20-40 GPa, whereas the one for the [134] orientation is 40-60 GPa. The threshold stress is calculated, considering the effect of shock heating. The constitutive description provides a rationale for the experimental results; the calculated thresholds are 18 GPa for [001] and 25 GPa for [134]. A mechanism for void generation and growth based on the emission of geometrically necessary dislocations is proposed and analytically formulated