Phase constitution,microstructure and mechanical properties of a Ni-based superalloy specially designed for additive manufacturing

In this study, a kind of Ni-based superalloy specially designed for additive manufacturing (AM) was investigated. Thermo-Calc simulation and differential scanning calorimetry (DSC) analysis were used to determine phases and their transformation temperature. Experimental specimens were prepared by laser metal deposition (LMD) and traditional casting method. Microstructure, phase constitution and mechanical properties of the alloy were characterized by scanning electron microscopy (SEM), transmission scanning electron microscopy (TEM), X-ray diffraction (XRD) and tensile tests. The results show that this alloy contains two basic phases, γ/γ', in addition to these phases, at least two secondary phases may be present, such as MC carbides and Laves phases. Furthermore, the as-deposited alloy has finer dendrite, its mean primary dendrite arm space (PDAS) is about 30-45 μm, and the average size of γ' particles is 100-150 nm. However, the dendrite size of the as-cast alloy is much larger and its PDAS is 300-500 μm with secondary and even third dendrite arms. Correspondingly, the alloy displays different tensile behavior with different processing methods, and the as-deposited specimen shows better ultimate tensile stress (1,085.7±51.7 MPa), yield stress (697±19.5 MPa) and elongation (25.8%±2.2%) than that of the as-cast specimen. The differences in mechanical properties of the alloy are due to the different morphology and size of dendrites, γ', and Laves phase, and the segregation of elements, etc. Such important information would be helpful for alloy application as well as new alloy development.     

Microstructure and mechanical properties of 3D-printed nano-silica reinforced alumina cores

Ceramic cores are an important component in the preparation of hollow turbine blades for aero-engines. Compared with traditional hot injection technology, 3D printing technology overcomes the disadvantages of a long production cycle and the difficulty in producing highly complex ceramic cores. The ceramic cores of hollow turbine blades require a high bending strength at high temperatures, and nano-mineralizers greatly improve their strength. In this study, nano-silica-reinforced alumina-based ceramic cores were prepared, and the effects of nanopowder content on the microstructure and properties of the ceramic cores were investigated. Alumina-based ceramic cores contained with nano-silica were prepared using the vat photopolymerization 3D printing technique and sintered at 1500 °C. The results showed that the linear shrinkage of ceramic cores first increased and then decreased as the nano-silica powder content increased, and the bending strength showed the same trend. The fracture mode changed from intergranular to transgranular. The open porosity and bulk density fluctuated slightly. The weight loss rate was approximately 20%. When the nano-silica content was 3%, the bending strength reached a maximum of 46.2 MPa and 26.1 MPa at 25 °C and 1500 °C, respectively. The precipitation of the glass phase, change in the fracture mode of the material, pinning crack of nanoparticles, and reduction of fracture energy due to the interlocking of cracks, were the main reasons for material strengthening. The successful preparation of 3D printed nano-silica reinforced alumina-based ceramic cores is expected to promote the preparation of high-performance ceramic cores with complex structures of hollow turbine blades.     

Flash cosintering of a lanthanum strontium cobalt ferrite nanofibre/Gd-doped ceria bilayer structure

For solid oxide fuel cells, an important structural requirement is that the electrolyte layer needs to be dense and the electrode layer porous, which is difficult to obtain by conventional cosintering. In this work, flash cosintering of a double layer structure consisting of a Gd-doped ceria substrate with a lanthanum strontium cobalt ferrite nanofibre coating is investigated. Experimental and finite element modelling results reveal that when the LSCF layer is connected to the electrode, the heat is concentrated in the LSCF layer, which leads to a huge temperature gradient and introduces severe cracking. When the LSCF layer is electrically isolated from the electrode, the heat is concentrated in the GDC layer, and the temperature gradient is dramatically reduced. In this situation, the density of GDC can reach 92.86% while a high porosity of 52.26% is maintained in the LSCF layer, which is higher than that of the conventional cosintered sample.     

Sealing behaviour of glass-based composites for oxygen transport membranes

In this study, seven different filler materials in different proportions were added to a Ba-Ca-Si glass matrix “H” to investigate new sealant with higher thermal expansion coefficient (CTE) value and good sealing performance for application in oxygen transport membrane (OTM). SrTi_0.75Fe_0.25O_3-δ (STF25) was used as an OTM, and the sealing partners were ferritic steel Aluchrom and pre-oxidized Aluchrom. Compatibility tests were carried out to investigate the feasibility of the composites. Higher CTE values were found in dilatometer tests on composite samples by adding 40 wt% Ag (HAg40) and 30 wt% Ni-Cr (HNC30). Gas-tightness measurements of sandwiched samples produced appropriate helium leakage rates in the range of 10^?6 mbar·l·s^?1. Sealing behaviour of sealants HAg40 and HNC30 were investigated by joining STF25 and as-delivered/pre-oxidized Aluchrom together. Scanning electron microscopy (SEM) on cross-sections of the joints revealed a homogeneous microstructure and good adherence of the glass sealants to support metals and STF25.     

Corrosion behavior of copper in extremely harsh marine atmosphere in Nansha Islands,China

The corrosion behavior of pure copper exposed to the atmosphere of Nansha Islands for 21 months was studied by mass loss method, composition analysis, morphology observation and electrochemical measurements. The results showed that the average corrosion rate of copper exposed for one year was approximately 7.85 μm/a, implying that Nansha Islands was classified as a corrosion category of CX. The structure and properties of the corrosion product layer generated on the front and back sides of the exposed sample differed significantly. The inner corrosion product layer (Cu₂O) on the front side was relatively thick and dense, whereas the outer product layer (Cu₂Cl(OH)₃) was extremely thin. However, the outer product layer on the back side was thicker than the inner layer. Electrochemical measurements indicated that the protection afforded by the corrosion product layer on the front side was improved gradually, while that on the back side was deteriorated.     

Zirconia-alumina multiphase ceramic fibers with exceptional thermal stability by melt-spinning from solid ceramic precursor

Zirconia-alumina multiphase ceramic fibers with 80 wt% (Z80A20 fiber) and 10 wt% (Z10A90 fiber) proportions of zirconia were prepared via melt-spinning and calcination from solid ceramic precursors synthesized by controllable hydrolysis of metallorganics. The zirconia-alumina multiphase fibers had a diameter of about 10 µm and were evenly distributed with alumina and zirconia grains. The Z80A20 and Z10A90 ceramic fibers had the highest filament tensile strength of 1.78 GPa and 1.87 GPa, respectively, with a peak value of 2.62 GPa and 2.71 GPa. The Z80A20 ceramic fiber has superior thermal stability compared to the Z10A90 ceramic fiber and a higher rate of filament strength retention due to the stability in grain size. After heat treatment at 1100 °C, 1200 °C, and 1300 °C for 1 h respectively, the filament tensile strength retention rate of Z80A20 ceramic fibers was 87 %, 80 %, and 40 %. While Z10A90 ceramic fiber was fragile after being heated at 1300 °C. The results showed that the high zirconia content facilitated the fiber's thermal stability.     

Ferroelectric domain structure and atomic-scale phase distribution in a Pb(Mg1/3Nb2/3)O3-PbTiO3 single crystal

Lead-based relaxor ferroelectric crystals, such as Pb(Mg_1/3Nb_2/3)O₃-PbTiO₃, are promising for functional applications due to their outstanding ferroelectric properties. Revealing ferroelectric domain structure and phase distribution at the nanoscale are important to understand the basic theory of ferroelectricity and promote their practical applications. In this study, the ferroelectric domain structure and atomic-scale phase distribution in a Pb(Mg_1/3Nb_2/3)O₃ - 35 at.% PbTiO₃ single crystal in the region of morphotropic phase boundary are systematically investigated by a combination of optical microscopy, scanning electron microscopy, and aberration-corrected transmission electron microscopy. It is found that 90° and 180° coarse domains are formed simultaneously in the ferroelectric single crystal. Moreover, there are tweed-like nano-domains formed inside each coarse single domain. Through careful investigations of distribution of stress and tetragonality, it is revealed that the tweed-like nano-domains are composed of nano-sized rhombohedral (R), monoclinic (M), and tetragonal (T) phases. The nano-scale T, M, R phases have the best, moderate, and lowest ferroelectricity, respectively.