Microstructure and oxide particle stability in a novel ODS γ-TiAl alloy processed by spark plasma sintering and laser additive manufacturing

In this work, a novel oxide dispersion strengthened titanium aluminide alloy (Ti-45Al-3Nb-<0.2Y2O3 at.%) was developed for powder-based processing technologies with a focus on spark plasma sintering and additive manufacturing. Titanium aluminides are promising structural intermetallics for weight reduction and an increased performance of high temperature components. The alloy design and selection process was supported by computational thermodynamics based on the CALPHAD approach, taking into account requirements for processing as well as long term alloy behavior under service conditions. Processing trials using spark plasma sintering, direct metal deposition and selective laser melting were conducted to study the alloy behavior, microstructure formation and introduction as well as stability of the ODS particles. Additionally, thermal annealing on the sintered and laser consolidated material was performed. Conventional dual phase α2-Ti3Al and γ-TiAl duplex and near-lamellar microstructures were obtained from the processed material. The ODS particles were homogeneously distributed in the alloy matrix after processing in the liquid state. For the direct metal deposition process, the novel alloy was compared to the established GE48-2-2 alloy (Ti-48Al-2Cr-2Nb) in terms of phases, microstructure and texture after processing. A significantly reduced texture formation was observed with the novel alloy. The hardness of the consolidated material shows superior properties for ODS-containing TiAl compared to ODS-free material. This work provides a first step towards tailored alloys for AM and the production of ODS TiAl alloys

Processing and microstructure characterisation of oxide dispersion strengthened Fe-14Cr-0.4Ti-0.25Y(2)O(3) ferritic steels fabricated by spark plasma sintering

Ferritic steels strengthened with Ti-Y-O nanoclusters are leading candidates for fission and fusion reactor components. A Fe-14Cr-0.4Ti + 0.25Y2O3 (14YT) alloy was fabricated by mechanical alloying and subsequently consolidated by spark plasma sintering (SPS). The densification of the 14YT alloys significantly improved with an increase in the sintering temperature. Scanning electron microscopy and electron backscatter diffraction revealed that 14YT SPS-sintered at 1150 °C under 50 MPa for 5 min had a high density (99.6%), a random grain orientation and a bimodal grain size distribution (&lt;500 nm and 1-20 μm). Synchrotron X-ray diffraction patterns showed bcc ferrite, Y2Ti2O7, FeO, and chromium carbides, while transmission electron microscopy and atom probe tomography showed uniformly dispersed Y2Ti2O7 nanoclusters of &lt;5 nm diameter and number density of 1.04 × 1023 m-3. Due to the very much shorter consolidation times and lower pressures used in SPS compared with the more usual hot isostatic pressing routes, SPS is shown to be a cost-effective technique for oxide dispersion strengthened (ODS) alloy manufacturing with microstructural features consistent with the best-performing ODS alloys