Coatings for Superalloys

High-temperature coatings for superalloys can be divided into three categories: Two of them, diffusion and overlay coatings, are both used to protect a system from oxidation and corrosion. The third type, thermal barrier coatings, protects the substrate from thermal degradation

Assessment of Mechanical TBC Failure in Complex Geometries

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Nitridation during oxidation as a challenge for Cr-based alloys and its mitigation by alloying

The high temperature behavior of pure chromium above 1000°C shows very interesting features such as vaporization, scale spallation and worst of all extreme nitridation when exposed to air. A detailed investigation of the different mechanisms can explain the wide range and controversial results given in the literature when the oxidation and its oxidation rates are reported for pure Chromium. Especially, the attack by nitridation deteriorates the mechanical properties by severe embrittlement. It also has a huge impact on the mass change during oxidation. To mitigate this embrittlement an alloying strategy is developed by the addition of silicon and germanium. The oxidation behavior of binary Cr-Si and ternary Cr-Ge-Si alloys at ultra-high temperatures (T=1200°C-1350°C) is reported (see also Figure 1) and the morphological evolution of the oxide scale and the metal subsurface zone was investigated using scanning electron microscopy, electron probe micro-analysis, and X-ray diffraction techniques. The A15-phase Cr3Si is shown to have a crucial influence on prevention of nitridation. During oxidation of a two phase Crss-Cr3Si system an A15 barrier develops in form of a continuous intermetallic layer underneath the surface. The in-situ formed barrier layers shown to be able to successfully prevent nitridation and the same time to improve the oxidation kinetics. Beyond that, ternary additions of Ge to the Cr-Si system strengthens this effect even more and significantly improves the oxidation kinetics of the chromium alloys at ultra-high temperatures to a level comparable to alumina formers (Figure 2). Please click Additional Files below to see the full abstract

Behavior of copper‐containing high‐entropy alloys in harsh metal‐dusting environments

Metal dusting is still an unresolved issue at high temperatures. Currently, two material‐related strategies to mitigate metal dusting are described in the literature. On the one hand, highly alloyed materials are used, which contain large amounts of protective oxide‐forming elements, such as Cr, Al, and Si. The second mitigation strategy is based on inhibiting the catalytic effect of Fe, Ni, and Co. These elements all strongly catalyze the formation of solid carbon from the gas phase. Combining the catalytic protection of Cu alloying for metal dusting with protection by a classical alumina/chromia barrier is a native feature that high‐entropy alloys (HEAs) can offer. In this study, the behavior of different equiatomic HEAs with and without Al and/or Cu are studied when exposed at 620°C in a highly aggressive metal‐dusting environment

Chromium-based bcc-superalloys strengthened by iron supplements

Chromium alloys are being considered for next-generation concentrated solar power applications operating > 800 °C. Cr offers advantages in melting point, cost, and oxidation resistance. However, improvements in mechanical performance are needed. Here, Cr-based body-centred-cubic (bcc) alloys of the type Cr(Fe)-NiAl are investigated, leading to ‘bcc-superalloys’ comprising a bcc-Cr(Fe) matrix (β) strengthened by ordered-bcc NiAl intermetallic precipitates (β’), with iron additions to tailor the precipitate volume fraction and mechanical properties at high temperatures. Computational design using CALculation of PHAse Diagram (CALPHAD) predicts that Fe increases the solubility of Ni and Al, increasing precipitate volume fraction, which is validated experimentally. Nano-scale, highly-coherent B2-NiAl precipitates with lattice misfit ∼ 0.1% are formed in the Cr(Fe) matrix. The Cr(Fe)-NiAl A2-B2 alloys show remarkably low coarsening rate (∼102 nm3/h at 1000 °C), outperforming ferritic-superalloys, cobalt- and nickel-based superalloys. Low interfacial energies of ∼ 40/20 mJ/m2 at 1000/1200 °C are determined based on the coarsening kinetics. The low coarsening rates are principally attributed to the low solubility of Ni and Al in the Cr matrix. The alloys show high compressive yield strength of ∼320 MPa at 1000 °C. The Fe-modified alloy exhibits resistance to age softening, related to the low coarsening rate as well as the relatively stable Orowan strengthening as a function of precipitate radius. Microstructure tailoring with Fe additions offers a new design route to improve the balance of properties in “Cr-superalloys”, accelerating their development as a new class of high-temperature materials

Chromium-based bcc-superalloys strengthened by iron supplements

Chromium alloys are being considered for next-generation concentrated solar power applications operating > 800 °C. Cr offers advantages in melting point, cost, and oxidation resistance. However, improvements in mechanical performance are needed. Here, Cr-based body-centred-cubic (bcc) alloys of the type Cr(Fe)-NiAl are investigated, leading to ‘bcc-superalloys’ comprising a bcc-Cr(Fe) matrix (β) strengthened by ordered-bcc NiAl intermetallic precipitates (β’), with iron additions to tailor the precipitate volume fraction and mechanical properties at high temperatures. Computational design using CALculation of PHAse Diagram (CALPHAD) predicts that Fe increases the solubility of Ni and Al, increasing precipitate volume fraction, which is validated experimentally. Nano-scale, highly-coherent B2-NiAl precipitates with lattice misfit ∼ 0.1% are formed in the Cr(Fe) matrix. The Cr(Fe)-NiAl A2-B2 alloys show remarkably low coarsening rate (∼102 nm3/h at 1000 °C), outperforming ferritic-superalloys, cobalt- and nickel-based superalloys. Low interfacial energies of ∼ 40/20 mJ/m2 at 1000/1200 °C are determined based on the coarsening kinetics. The low coarsening rates are principally attributed to the low solubility of Ni and Al in the Cr matrix. The alloys show high compressive yield strength of ∼320 MPa at 1000 °C. The Fe-modified alloy exhibits resistance to age softening, related to the low coarsening rate as well as the relatively stable Orowan strengthening as a function of precipitate radius. Microstructure tailoring with Fe additions offers a new design route to improve the balance of properties in “Cr-superalloys”, accelerating their development as a new class of high-temperature materials

From eutectic to peritectic: Effect of Ge on morphology, structure, and coarsening of Cr-Cr3Si alloys

The influence of germanium on microstructure, crystallography, and thermal stability of the eutectic Cr-Cr3Si alloy was investigated. Fine eutectic microstructures could be preserved but slightly degenerated when up to 2 at.% Si was substituted by Ge. A transition from eutectic to peritectic microstructure composed of primary dendrites and A15 Cr3Si matrix was observed when higher amounts of Ge were added. X-ray diffraction results showed no limit for substitution of Si and Ge in the studied composition range. The lattice parameter of both Cr solid-solution and A15 silicide increased with increasing the Ge/Si ratio. A macro was developed for the ImageJ program to automate the quantitative microstructural image analysis. Results showed that Ge addition increases the A15 phase fraction of the two-phase alloys. Microstructural investigations on annealed alloys at 1350 degrees C demonstrated that the coarsening of both binary Cr-Cr3Si and ternary Cr-Cr-3(Si, Ge) is interface-controlled. Although Ge addition to the eutectic alloy offered an isotropic microstructure, it decreased the thermal stability by degeneration of the lamellar structure