Microstructural and mechanical characterization of alumina scales thermally developed on iron aluminide alloys

Several alumina-forming Fe-Al intermetallic alloys have been oxidized in oxygen for 100 h at 1000 C to understand the scaling kinetics, scale morphology, scale adhesion, and strain accommodation in the scales. Oxidation studies were conducted by thermogravimetry, followed by analyses of the surfaces of oxide scales. In addition, samples were cooled to 77 K and then fractured; then, their scale/metal interfaces were analyzed. Some of the scales were adhesion-tested by applying a tensile load to pull the scale away from the substrate. Finally, ruby fluorescence was used to measure in-plane strains in the oxide scales and values correlated with scale microstructures

Effect of water vapor on the spallation of thermal barrier coating systems during laboratory cyclic oxidation testing.

The effect of water and water vapor on the lifetime of Ni-based superalloy samples coated with a typical thermal barrier coating system—b-(Ni,Pt)Al bond coat and yttria stabilized zirconia (YSZ) top coat deposited by electron beam physical vapor deposition (EB-PVD) was studied. Samples were thermally cycled to 1,150 C and subjected to a water-drop test in order to elucidate the effect of water vapor on thermal barrier coating (TBC) spallation. It was shown that the addition of water promotes spallation of TBC samples after a given number of cycles at 1,150 C. This threshold was found to be equal to 170 cycles for the present system. Systems based on b-NiAl bond coat or on Pt-rich c/c0 bond coat were also sensitive to the water-drop test. Moreover, it was shown that water vapor in ambient air after minutes or hours at room temperature, promotes also TBC spallation once the critical number of cycles has been reached. This desktop spalling (DTS) can be prevented by locking up the cycled samples in a dry atmosphere box. These results for TBC systems confirm and document Smialek’s theory about DTS and moisture induced delayed spalling (MIDS) being the same phenomenon. Finally, the mechanisms implying hydrogen embrittlement or surface tension modifications are discussed

Stress Determination in Thermally Grown Alumina Scales Using Ruby Luminescence

By exploiting the strain dependence of the ruby luminescence line, we have measured the strain in alumina scales thermally grown on Fe-Cr- Al alloys. Results are compared and found to be reasonably consistent with strains determined using x rays. Oxidation studies were carried out on alloys Fe - 5Cr - 28Al and Fe - 18Cr - 10Al (at.%). Significantly different levels of strain buildup were observed in scales on these alloys. Results on similar alloys containing a ``reactive element`` (Zr or Hf) in dilute quantity are also presented. Scales on alloys containing a reactive element (RE) can support significantly higher strains than scales on RE-free alloys. With the luminescence technique, strain relief associated with spallation thresholds is readily observed

Strain measurements in thermally grown alumina scales using ruby fluorescence

We have measured strains in alumina scales thermally grown on Fe-Cr- Al alloys by exploiting the strain dependence of the ruby luminescence line. Measurements were done on Fe-5Cr-28Al and Fe-18Cr-10Al (at.%, bal. Fe) oxidized between 300-1300 C with periodic cycling to room temperature. Significantly different levels of strain buildup were observed in scales on these alloys. Results on similar alloys containing a dilute reactive element (Zr or Hf) are also presented. We observe that scales on alloys containing a reactive element (RE) can support higher strains than scales on RE-free alloys. With the luminescence technique, strain relief associated with spallation thresholds is readily observed. In early stage oxidation, the evolution of transition phases is monitored using Raman and fluorescence spectroscopies. The fluorescence technique also provides a sensitive probe of early stage formation of {alpha}-Al{sub 2}O{sub 3}. It appears that, in presence of Cr{sub 2}O{sub 3} or Fe{sub 2}O{sub 3}, the {alpha}-alumina phase can form at anomalously low temperatures

Stress determination in thermally grown alumina scales using ruby luminescence

By exploiting the strain dependence of the ruby luminescence line, we have measured the strain in alumina scales thermally grown on Fe-Cr- Al alloys. Results are compared and found to be reasonably consistent with strains determined using x rays. Oxidation studies were carried out on alloys Fe - 5Cr - 28Al and Fe - 18Cr - 10Al (at.%). Significantly different levels of strain buildup were observed in scales on these alloys. Results on similar alloys containing a ``reactive element`` (Zr or Hf) in dilute quantity are also presented. Scales on alloys containing a reactive element (RE) can support significantly higher strains than scales on RE-free alloys. With the luminescence technique, strain relief associated with spallation thresholds is readily observed