The Effect of Nb Addition on the Microstructure and the High-Temperature Strength of Fe3Al Aluminide

Metallurgical and Materials Transactions A - The microstructural and high-temperature mechanical properties of Fe–26Al–xNb (x = 3 and 5 at. pct) are...     

Fe<Subscript>3</Subscript>Al Iron Aluminides Alloyed with High Concentrations of V and Cr: Their Structure and High Temperature Strength

Eight iron aluminide alloys with different contents of V and Cr were prepared up to 25 at. pct of both elements. The effect of the V and Cr concentration on the microstructure and mechanical properties was investigated by several complementary techniques. This investigation revealed that the microstructure of all the investigated alloys was comparable regardless of their chemical composition. All the alloys were in a solid solution condition without any major chemical inhomogeneity. For all alloys, a comparable grain size and D0₃ crystallographic structure was observed. In situ X-ray diffraction measurement revealed that the crystallographic structure was stable up to 1073 K (800 °C) regardless of the chemical composition. Mechanical testing showed that the compressive yield stress significantly increased with the increasing total sum of V plus Cr. Much higher values of yield stress were measured for symmetric concentrations of V and Cr when compared to non-symmetric ones. Eventually, it was shown that the formation of at least a rough system of the lattice positions occupation by four types of atoms in four sub-lattices derived from D0₃ is the most probable strengthening factor for alloys with symmetric concentrations of V and Cr.     

Infrared Brazing Fe<Subscript>3</Subscript>Al Using Ag-Based Filler Metals

The microstructural evolution and bonding shear strength of infrared brazed Fe₃Al using Ag and BAg-8 (72Ag-28Cu in wt pct) braze alloys have been studied. The Ag-rich phase alloyed with Al dominates the entire Ag brazed joints, and the shear strength is independent of the brazing time. The BAg-8 brazed joint contains Ag-Cu eutectic for all brazing conditions, and its shear strength increases slightly with increasing brazing time. The highest shear strength of 181 MPa is acquired from the joint infrared brazed at 1073 K (800 °C) for 600 seconds. A thin layer of Fe₃Al is identified at the interface between the brazed zone and the substrate for both braze alloys. An Al depletion zone in the Fe₃Al substrate next to the interfacial Fe₃Al is identified as the α-Fe phase. The dissolution of Al from the Fe₃Al substrate into the molten braze causes the formation of α-Fe in the Fe₃Al substrate.     

Effect of alloying additions on the structure and mechanical properties of Fe<Subscript>3</Subscript>Al -1C intermetallic alloy

Effect of titanium and nickel on the structure and properties of Fe₃Al intermetallic alloy containing about 1.0wt.% C have been investigated. The composition of the alloying element was substituted for Iron. The alloys were prepared by melting commercial grade raw materials iron, aluminum, titanium or nickel in air induction furnace with flux cover (AIMFC). Further these ingots were refined by electroslag refining (ESR) process. These ingots could be successfully hot-worked using conventional hot-forging and hot-rolling techniques. The hot-worked material was sound and free from cracks. ESR hot-rolled alloys were examined using optical microscopy, X-ray diffraction (XRD), scanning electron micrograph (SEM) to understand the microstructure of these alloys. The electron probe micro analysis (EPMA) studies were carried out to determine the matrix and precipitate compositions and to identify the phases present in the alloys. The base alloy and the alloy containing Ni exhibited a two-phase microstructure of Fe₃AlC_0.5 precipitates in Fe₃Al matrix. The alloy containing Ti exhibits three-phase microstructure, the additional phase being TiC precipitate. Ti addition resulted in no improvement in strength at room temperature and at 873 K whereas Ni addition has resulted in greater improvement in strength at room temperature and at 873 K and also improved the creep life significantly from 66 hrs to 111 hrs.     

Salt Bath Nitriding of Fe<Subscript>3</Subscript>Al Based Intermetallic Compound

Iron aluminide Fe₃Al was produced in a vacuum arc melting furnace. The alloy was heat treated by salt bath nitriding at 580 °C for durations of 3, 6, and 9 h. The nitride layers formed on the surface were characterized with light optical microscopy (LOM), scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectroscopy (EDXS), X-ray diffraction (XRD), and micro hardness measurements. The results showed that the nitride layer thickness increased with an increase in nitriding duration, while the layer hardness did not vary. The nitride layers were composed chiefly of iron nitride and aluminum nitride phases. The dry sliding friction and wear behaviors of nitrided iron aluminides were determined. The results revealed that the wear resistance decreased with increase in the length of nitriding.     

Strengthening of Fe<Subscript>3</Subscript>Al Aluminides by One or Two Solute Elements

The compressive yield stress of Fe-26Al with additives Ti (0.5 to 4 at. pct), Cr (0.5 to 8 at. pct), Mo (0.5 to 4 at. pct), and V (0.5 to 8 at. pct) at 1073 K (800 °C) has been determined. The effect of the concentration of diverse solutes on the yield stress at 1073 K (800 °C) was compared, and the additivity of the effects of solutes was tested. The effects in iron aluminides with two solutes (V and Ti, Ti and Cr, V and Cr) are compared with those of a single solute V, Ti, and Cr. It is found that the additivity of yield stress increments is valid only for lower solute concentrations. When the amount of the solute atoms increases, the yield stress increment is substantially higher than the sum of the yield stress increments of single solutes. This behavior is related to the high-temperature order in iron aluminides.     

Effect of Planar Flow Melt Spinning Parameters on Ribbon Formation in Soft Magnetic Fe<Subscript>68.5</Subscript>Si<Subscript>18.5</Subscript>B<Subscript>9</Subscript>Nb<Subscript>3</Subscript>Cu<Subscript>1</Subscript> Alloy

The effect of planar flow melt spinning (PFMS) parameters on the continuity, surface quality, and structure of 10-mm-wide Fe_68.5Si_18.5B₉Nb₃Cu₁ ribbons has been investigated. The change in shape and stability of the melt puddle as a function of the processing parameter was studied using a high-speed imaging system and was correlated to ribbon formation. A window of process parameters for obtaining continuous ribbons with good surface quality has been evaluated. It has been observed that thinner ribbons are found to be more continuous because of higher ductility. The higher melt temperature leads to the formation of crystalline phase in as-spun ribbons, and this deteriorates the soft magnetic properties on annealing. The experimental results are corroborated with the numerical estimates, which suggest that the critical thickness for amorphous phase formation decreases with increasing initial melt temperature.     

Effect of Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Concentration on Density and Structure of (CaO-SiO<Subscript>2</Subscript>)-xAl<Subscript>2</Subscript>O<Subscript>3</Subscript> Slag

The effect of Al₂O₃ concentration on the density and structure of CaO-SiO₂-Al₂O₃ slag was investigated at multiple Al₂O₃ mole percentages and at a fixed CaO/SiO₂ ratio of 1. The experiments were conducted in the temperature range of 2154 K to 2423 K (1881 °C to 2150 °C) using the aerodynamic levitation technique. In order to understand the relationship between density and structure, structural analysis of the silicate melts was carried out using Raman spectroscopy. The density of each slag sample investigated in this study decreased linearly with increasing temperature. When the Al₂O₃ content was less than 15 mole pct, density decreased with increasing Al₂O₃ content due to the coupling of Si (Al), whereas above 20 mole pct density of the slag increased due to the role of Al³⁺ ion as a network modifier.     

Effect of Ce<Subscript>2</Subscript>O<Subscript>3</Subscript> on Structure,Viscosity, and Crystalline Phase of CaO-Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-Li<Subscript>2</Subscript>O-Ce<Subscript>2</Subscript>O<Subscript>3</Subscript> Slags

Aiming at devising new mold flux for Ce-bearing stainless steel, a fundamental investigation on the effect of Ce₂O₃ on properties of the CaO-Al₂O₃-Li₂O-Ce₂O₃ slag was provided by the present work. The results show that adding Ce₂O₃ could decrease the viscosity of the slag due to its effects on decreasing the polymerization of the slag. The crystalline process was restrained by increasing the content of Ce₂O₃, and the crystalline phases also can be influenced by the slag structure. The crystalline phases were transferred from LiAlO₂ and CaO to LiAlO₂ and CaCeAlO₄ with the addition of Ce₂O₃ to the slag, which could be well confirmed by the structure of the unit cell of the crystals.     

Heterogeneous Creep Deformations and Correlation to Microstructures in Fe-30Cr-3Al Alloys Strengthened by an Fe<Subscript>2</Subscript>Nb Laves Phase

A new Fe-Cr-Al (FCA) alloy system has been developed with good oxidation resistance and creep strength at high temperature. The alloy system is a candidate for use in future fossil-fueled power plants. The creep strength of these alloys at 973 K (700 °C) was found to be comparable with traditional 9 pct Cr ferritic–martensitic steels. A few FCA alloys with general composition of Fe-30Cr-3Al-.2Si-xNb (x = 0, 1, or 2) with a ferrite matrix and Fe₂Nb-type Laves precipitates were prepared. The detailed microstructural characterization of samples, before and after creep rupture testing, indicated precipitation of the Laves phase within the matrix, Laves phase at the grain boundaries, and a 0.5 to 1.5 μm wide precipitate-free zone (PFZ) parallel to all the grain boundaries. In these alloys, the areal fraction of grain boundary Laves phase and the width of the PFZ controlled the cavitation nucleation and eventual grain boundary ductile failure. A phenomenological model was used to compare the creep strain rates controlled by the effects of the particles on the dislocations within the grain and at grain boundaries. (The research sponsored by US-DOE, Office of Fossil Energy, the Crosscutting Research Program).     

Effect of Superficially Applied Y<Subscript>2</Subscript>O<Subscript>3</Subscript> Coating on High-Temperature Corrosion Behavior of Ni-Base Superalloys

Inhibitors and oxide additives have been investigated with varying success to control high-temperature corrosion. Effect of Y₂O₃ on high-temperature corrosion of Superni 718 and Superni 601 superalloys was investigated in the Na₂SO₄-60 pct V₂O₅ environment at 1173 K (900 °C) for 50 cycles. Y₂O₃ was applied as a coating on the surfaces of the specimens. Superni 601 was found to have better corrosion resistance in comparison with Superni 718 in the Na₂SO₄-60 pct V₂O₅ environment. The Y₂O₃ superficial coating was successful in decreasing the reaction rate for both the superalloys. In the oxide scale of the alloy Superni 601, Y and V were observed to coexist, thereby indicating the formation of a protective YVO₄ phase. There was a distinct presence of a protective Cr₂O₃-rich layer just above the substrate/scale interface in the alloy. Whereas Cr₂O₃ was present with Fe and Ni in the scale of Superni 718. Y₂O₃ seemed to be contributing to better adhesion of the scale, as comparatively lesser spalling was noticed in the presence of Y₂O₃.     

Effect of Firing Temperature and Reducing Gas Composition during Low-Temperature Reduction of Nanocrystalline Fe<Subscript>2</Subscript>O<Subscript>3</Subscript>

Pure nanocrystalline hematite (40 to 100 nm) compacts were prepared and sintered at various temperatures (300 °C to 600 °C) and then reduced with 100 pct H₂ at 500 °C. On the other hand, fired compacts at 500 °C were reduced with a H₂-Ar gas mixture containing different concentration of hydrogen (100, 75, 50, and 25 pct) at 500 °C using thermogravimetric techniques. Nanocrystalline Fe₂O₃ compacts were characterized before and after reduction with X-ray diffraction, scanning electron microscopy (SEM), vibrating sample magnetometer (VSM), and reflected light microscope. It was found that the fired compacts at 400 °C to 600 °C have relatively faster reaction behaviors compared to that at lower firing temperature 300 °C. By decreasing the firing temperature to 300 °C, partial sintering with grain growth was observed clearly during reduction. Also, it was found that the reduction rate increased with increasing hydrogen content in the reducing gas. Comparatively, grain growth and partial coalescence took place during reduction with 25 pct H₂ due to long reaction time.

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Structure and magnetic properties of the Nd<Subscript>9.5</Subscript>Fe<Subscript>84.5</Subscript>B<Subscript>6</Subscript> alloy subjected to severe plastic deformation and annealing

The effect of severe plastic deformation (SPD) by torsion and subsequent annealing on the structure and magnetic properties of the cast Nd_9.5Fe_84.5B₆ alloy is studied. SPD by torsion is shown to lead to partial amorphization of the Nd₂Fe¹⁴B phase and the precipitation of α-Fe; subsequent annealing results in the crystallization of the amorphous phase and the formation of a nanocomposite Nd₂Fe₁₄B/α-Fe structure. After SPD by torsion at 20 revolutions and annealing at 873 K, the (101) texture is formed; in this case, the coercive force is H _c = 360 kA/m and the maximum energy product is (BH) _max = 166 kJ/m3. The residual magnetization and the squareness ratio of the hysteretic loop of the textured alloy decrease as the ambient temperature decreases.     

Influence of heat treatment on the efficiency of impact fragmentation of amorphous alloy Fe<Subscript>73.5</Subscript>Cu<Subscript>1</Subscript>Nb<Subscript>3</Subscript>Si<Subscript>13.5</Subscript>B<Subscript>9</Subscript> ribbons

The mechanism of impact fracture of soft magnetic amorphous alloy Fe_73.5Cu₁Nb₃Si_13.5B₉ ribbons in a disintegrator after heat treatment at a temperature from the range 300–700°C and the fractional composition of the formed powder are studied. The temperature ranges of a change in the mechanism of ribbon fracture are determined. The particle size distribution is shown to change weakly within the revealed temperature ranges.     

Effects of Zr on the eutectoid decomposition behavior of Nb<Subscript>3</Subscript>Si into (Nb)/Nb<Subscript>5</Subscript>Si<Subscript>3</Subscript>

The effect of Zr on the formation of Nb/Nb₅Si₃ lamellar microstructure by eutectoid decomposition reaction of Nb₃Si is investigated. It has been shown that the kinetics of the eutectoid decomposition of high-temperature Nb₃Si phase into Nb and Nb₅Si₃ phases are sluggish in the binary Nb-Si system and that they are enhanced by Zr additions. The time-temperature-transformation (TTT) diagram for the decomposition is experimentally determined and the acceleration of the reaction by small Zr addition of 1.5 at. pct is confirmed by comparison with the reported TTT curves of binary and ternary alloys containing Ti. The role of the ternary element on the decomposition kinetics is discussed in terms of crystallographic orientation relationships (ORs) and Zr distribution in the parent Nb₃Si phase during solidification. This article is based on a presentation made in the symposium entitled “Beyond Nickel-Base Superalloys,” which took place March 14–18, 2004, at the TMS Spring meeting in Charlotte, NC, under the auspices of the SMD-Corrosion and Environmental Effects Committee, the SMD-High Temperature Alloys Committee, the SMD-Mechanical Behavior of Materials Committee, and the SMD-Refractory Metals Committee.     

Reduction of Fe<Subscript>2</Subscript>MoO<Subscript>4</Subscript> by hydrogen gas

In the present work, the reduction kinetics of iron molybdate (Fe₂MoO₄) by hydrogen gas was investigated by thermogravimetric analyses (TGA). Both isothermal and nonisothermal experiments were conducted. By using fine particles, very shallow powder bed, and high hydrogen flow rate, the study could be focused on the chemical reaction. The activation energy obtained from the isothermal experiments was found to be 173.5 kJ/mol, which was in reasonable agreement with the value of 158.3 kJ/mol obtained from the nonisothermal experiments. The reduction product was found to be an intermetallic compound, Fe₂Mo, of microcrystalline structure.