The Influence of Specimen Thickness on the High Temperature Corrosion Behavior of CMSX-4 during Thermal-Cycling Exposure

CMSX-4 is a single-crystalline Ni-base superalloy designed to be used at very high temperatures and high mechanical loadings. Its excellent corrosion resistance is due to external alumina-scale formation, which however can become less protective under thermal-cycling conditions. The metallic substrate in combination with its superficial oxide scale has to be considered as a composite suffering high stresses. Factors like different coefficients of thermal expansion between oxide and substrate during temperature changes or growing stresses affect the integrity of the oxide scale. This must also be strongly influenced by the thickness of the oxide scale and the substrate as well as the ability to relief such stresses, e.g., by creep deformation. In order to quantify these effects, thin-walled specimens of different thickness (t = 100500 lm) were prepared. Discontinuous measurements of their mass changes were carried out under thermal-cycling conditions at a hot dwell temperature of 1100 C up to 300 thermal cycles. Thin-walled specimens revealed a much lower oxide-spallation rate compared to thick-walled specimens, while thinwalled specimens might show a premature depletion of scale-forming elements. In order to determine which of these competetive factor is more detrimental in terms of a component’s lifetime, the degradation by internal precipitation was studied using scanning electron microscopy (SEM) in combination with energy-dispersive X-ray spectroscopy (EDS). Additionally, a recently developed statistical spallation model was applied to experimental data [D. Poquillon and D. Monceau, Oxidation of Metals, 59, 409–431 (2003)]. The model describes the overall mass change by oxide scale spallation during thermal cycling exposure and is a useful simulation tool for oxide scale spallation processes accounting for variations in the specimen geometry. The evolution of the net-mass change vs. the number of thermal cycles seems to be strongly dependent on the sample thickness

Analysis of acoustic emission during the melting of embedded indium particles in an aluminum matrix: a study of plastic strain accommodation during phase transformation

Acoustic emission is used here to study melting and solidification of embedded indium particles in the size range of 0.2 to 3 um in diameter and to show that dislocation generation occurs in the aluminum matrix to accommodate a 2.5% volume change. The volume averaged acoustic energy produced by indium particle melting is similar to that reported for bainite formation upon continuous cooling. A mechanism of prismatic loop generation is proposed to accommodate the volume change and an upper limit to the geometrically necessary increase in dislocation density is calculated as 4.1 x 10^9 cm^-2 for the Al-17In alloy. Thermomechanical processing is also used to change the size and distribution of the indium particles within the aluminum matrix. Dislocation generation with accompanied acoustic emission occurs when the melting indium particles are associated with grain boundaries or upon solidification where the solid-liquid interfaces act as free surfaces to facilitate dislocation generation. Acoustic emission is not observed for indium particles that require super heating and exhibit elevated melting temperatures. The acoustic emission work corroborates previously proposed relaxation mechanisms from prior internal friction studies and that the superheat observed for melting of these micron-sized particles is a result of matrix constraint.Comment: Presented at "Atomistic Effects in Migrating Interphase Interfaces - Recent Progress and Future Study" TMS 201

Selecting Appropriate Metallic Alloy for Marine Gas Turbine Engine Compressor Components

Metallic alloys with excellent structural and chemical properties play a significant role in a variety of applications. The selection of suitable metallic materials for marine gas turbine engine components is a real challenge as the surrounding environment is highly corrosive and the components have to function for a designed period at varied elevated temperatures. This chapter explains the selection of a suitable metallic alloy for marine gas turbine engine compressor section components based on extensive experimental data on two titanium‐based alloys 6242 and IMI 834 under simulated marine gas turbine engine environmental conditions. The results revealed that 6242 exhibits superior performance over IMI 834. Therefore, the titanium alloy 6242 in association with appropriate protective coating is recommended to fabricate components intended to use for marine gas turbine engine compressor section applications

Evaluation of laser-glazed plasma-sprayed thermal barriercoatings under high temperature exposure to molten salts

Thermal Barrier Coating (TBC) systems are frequently used in gas turbine engines to provide thermal insulation to the hot-section metallic components and also to protect them from oxidation, hot corrosion and erosion. Surface sealing treatments, namely laser-glazing, have been showing a high potential for extending in-service lifetimes of these systems by improving chemical and thermo-mechanical resistance. In this investigation, both as-sprayed and laser-glazed TBCs were exposed to hot corrosion in molten salts. The glazed coatings were obtained by scanning the surface of the plasma-sprayed coatings with either a CO2 or a Nd:YAG laser. The hot corrosion investigation was accomplished by subjecting the specimens to an isothermal air furnace testing under V2O5 and/or Na2SO4 at a temperature of 1000 °C for 100 h. Spallation has been observed in coatings in the as-sprayed condition under V2O5 or V2O5+Na2SO4. Na2SO4 itself had no or minimal effect on the degradation of the laser-glazed or as-sprayed condition coatings, respectively. The degradation in V2O5 was accomplished by destabilization of YSZ as a consequence of depletion of yttria from the solid solution to form YVO4 and therefore led to the disruptive transformation of the metastable tetragonal phase to the monoclinic phase. Moreover, the presence of both corrosive salts induced the formation of large high aspect ratio YVO4 crystals that introduced additional stresses and contributed to the degradation of the coatings. The laser-glazed specimens were not efficient in avoiding the molten salt penetration along the thickness direction due to the presence of cracks on the glazed layer. However due to a reduced specific surface area of the dense glazed layer, the corrosion reaction of the molten salts with the YSZ has been lower than in coatings in the assprayed condition.Fundo Europeu de Desenvolvimento Regional(FEDER) - Programa Operacional "Ciência, Tecnologia e Inovação" (POCTI).Fundação para a Ciência e a Tecnologia (FCT) - Project POCTI/CTM/ 44590/2002