High temperature oxidation of an oxide-dispersion strengthened NiAl

The oxidation behavior of an oxide-dispersion strengthened (ODS) NiAl has been studied between 900 and 1100°C in air. The dispersoids of mostly Al₂O₃ in fine-grained β-NiAl were incorporated by mechanical alloying (MA) in an argon atmosphere and hot pressing. It was found that excessive amounts of dispersoids and voids within the matrix had serious negative effects on the oxidation resistance of β-NiAl, by allowing for a more rapid formation of oxide scales and by providing fast diffusion paths for oxygen. Below the thin surface oxide scales consisted of -Al₂O₃, NiAl₂O₄ and Ni₂O₃, an internal oxidation zone was formed deep into the matrix. No metastable transient aluminas were formed during oxidation. The oxide ridge structure began to evolve after oxidation at 1100°C at the oxide–gas interface.     

Formation of interfacial voids in cast and micro-grained γ′-Ni3Al during high temperature oxidation

Specimens of cast and micro-grained γ′-Ni₃Al, which were produced with vacuum casting and unbalanced magnetron sputter deposition, respectively, were isothermally oxidised in air at 1473 K for different periods of time. The formation of interfacial voids at the alloy/oxide interface was observed with SEM, which indicated that there were more interfacial voids formed in the cast Ni₃Al than in the micro-grained alloy under the same oxidation conditions. A phenomenological equation describing the fraction of the void projected areas was established, in which the impingement and coalescence between voids during their growth was taken into consideration. It was elucidated that low vacancy density in the micro-grained Ni₃Al due to the high creep, re-crystallisation and the enhanced Al diffusion reduced the void percentage. Also, it was confirmed that aluminium evaporation, perhaps supplemented by surface diffusion, supplied most Al to the oxide scales formed above the interfacial voids.     

Formation of NiAl intermetallic by gradual and explosive exothermic reaction mechanism during ball milling

NiAl intermetallic has been produced by mechanical alloying in a high energy vibrator mill using elemental Ni and Al powder mixture. The NiAl powders were formed in two ways. One by a gradual exothermic reaction mechanism during a long time continuous milling and the other by explosive exothermic reaction mechanism that occurred when opening the milling vessel to the air atmosphere after a short time milling. Prolonged milling for both cases resulted in change of morphology and refinement of grain size down to nano scale.     

Platinum-catalyzed high temperature oxidation of metals

Samples of Al, Cr, Ni, and Zr were sputter-coated with porous Pt-films with a particle size of 20-30 nm. Thermal oxidation of these samples was studied by gas phase analysis (GPA) and secondary ion mass spectrometry (SIMS). SIMS analysis on partly Pt-coated samples of Al, Cr, Ni, and Zr at different oxide depths in areas with Pt and in areas away from Pt indicates an enhanced inward oxide growth in the Pt area and mm-ranged distance from Pt-area. Weight gain measurements on Pt-coated Ni samples show a reduced or increased oxidation rate depending on the amount of porous Pt-coating. Pt has two effects on the thermal oxidation of metals and the overall effect of Pt on the oxidation of metals depends on the mechanism of oxide growth in the absence of Pt.     

On the oxidation mechanism of Ni–Pt alloys at high temperatures

The oxidation mechanism of Ni–Pt alloys has been studied as a function of alloy composition, oxygen pressure and temperature. It has been found that the oxidation rate of all the alloys follows the parabolic rate law, being thus diffusion controlled. In agreement with Wagner’s theory, the slowest step of the overall oxidation rate of alloys with higher nickel content (?40 at.%) is determined by the outward diffusion of nickel cations in the growing NiO scale. On the other hand, the oxidation rate of alloys with a lower nickel content (<40 at.%) is governed by the solid state diffusion in the metallic phase.     

The effect of Si additions on the high temperature oxidation of a ternary Ni-10Cr-4Al alloy in 1 atm O2 at 1100 °C

The oxidation of four Ni-10Cr-ySi-4Al alloys was studied at 1100 °C to examine the effects of Si additions (from 2 to 6 at.%) on the behavior of the alloy Ni-10Cr-4Al. Addition of 2 at.% Si prevented completely nickel oxidation, but could not form alumina scales. Larger Si additions produced alumina only over part of the alloy surface (about 20% with 4 at.% Si and 30% with 6 at.% Si), but could not prevent completely the internal oxidation of Al. The results are interpreted by extending to quaternary alloys the mechanism of the third-element effect already proposed for ternary alloys.     

Model of oxidation of SiC microparticles at high temperature

The oxidation kinetics of SiC microparticles has been studied from both experimental data and theoretical aspects based on recent research work. The effects of temperature, especially the particle size on the oxidation kinetics are explained not only qualitatively but also quantitatively based on our theory and model. The results show that our new model and the calculated results can reach a good agreement. It may also be seen that the important role of particle size in oxidation of SiC powder, especially in the nano era for SiC material.     

The role of microstructure in the high temperature oxidation mechanism of Cr3C2-NiCr composite coatings

Composites of Cr₃C₂-NiCr provide superior oxidation resistance to WC-Co composites, which has seen them applied extensively to components subjected to combined high temperature erosion and oxidation. This work characterises the variation in oxidation mechanism of thermally sprayed Cr₃C₂-NiCr composites at 700 °C and 850 °C as a function of heat treatment. Carbide dissolution during spraying increased the Ni alloy Cr concentration, minimising the formation of Ni oxides during oxidation. Compressive growth stresses resulted in ballooning of the oxide over the carbide grains. Carbide nucleation with heat treatment reduced the Ni alloy Cr concentration. The oxidation mechanism of the composite coating changed from being Cr based to that observed for NiCr alloys.     

The effect of nanostructure on the oxidation of NiAl

Bulk nanostructured NiAl samples with a grain size of 104 nm have been obtained through cryomilling of NiAl intermetallic feedstock powder and subsequent sintering via SPS. Oxidation testing of these conventional and nanostructured NiAl samples reveals that while the conventional samples have oxidation rates on the order of 10⁻¹¹ g²/cm⁴/s across all tested temperatures, nanostructured samples demonstrate decreasing oxidation rates with temperature, as low as 6.78 × 10⁻¹³ g²/cm⁴/s. This decrease in oxidation rate is attributed to an earlier transition through the metastable aluminum oxide phases, resulting in a stable slow growing α-Al₂O₃ phase earlier in the oxidation tests. In-situ X-ray diffraction (XRD) during high temperature oxidation testing has shown that lattice strain at the surface of the nanostructured samples is substantially higher than conventional, and that the decrease of this lattice strain with temperature is significant. It is believed that the relief of this lattice strain stimulates the earlier θ–α transition seen in the nanostructured samples.     

Quantification of growth kinetics and adherence of oxide scales formed on Ni-based superalloys at high temperature

Cyclic and isothermal oxidation behaviors of first and fourth-generation superalloys AM1 and MCNG were investigated to evaluate the ability of the scratch test to quantify the adhesion of multi-layered oxide scales. Effects of sulfur content and of scale thickness were studied independently. Available models lead to large discrepancies in the calculated work of adhesion values with the evaluation of the residual stress being the largest source of error. Nevertheless, models can assess the effect of sulfur content and the scratch test can be used to correlate the long-term cyclic oxidation behavior and the adhesion of oxide scales.     

Effects of Ni vacancy,Ni antisite,Cr and Pt on the third-order elastic constants and mechanical properties of NiAl

Effects of Ni vacancy, Ni antisite in Al sublattice, Cr in Al sublattice, Pt in Ni sublattice on the second-order elastic constants (SOECs) and third-order elastic constants (TOECs) of the B2 NiAl have been investigated using the first-principles methods. Lattice constant and the SOECs of NiAl are in good agreement with the previous results. The brittle/ductile transition map based on Pugh ratio G/B and Cauchy pressure P_c shows that Ni antisite, Cr, Pt and pressure can improve the ductility of NiAl, respectively. Ni vacancy and lower pressure can enhance the Vickers hardness H_v of NiAl. The density of states (DOS) and the charge density difference are also used to analysis the effects of vacancy, Ni antisite, Cr and Pt on the mechanical properties of NiAl, and the results are in consistent with the transition map.     

Experimental study and modeling of high temperature oxidation of Nb-base in situ composites

The oxidation behavior of Nb-base in situ composites in static air at 1100, 1200 and 1250 °C has been studied. The reaction followed the parabolic rate law. The oxide scales were mainly composed of TiNb₂O₇, TiNb₁₀O₂₉, TiO₂, Nb₂O₅ and SiO₂. The theoretical oxidation model proposed by Gesmundo et al. has been applied to analyze existing oxidation data of Nb-base in situ composites. The result shows that oxidation rate of the Nb-base in situ composites is basically accordance with the analytical results predicted by the theoretical oxidation model to a good approximation.     

Investigations on the microstructure and room temperature fracture toughness of directionally solidified NiAl–Cr(Mo) eutectic alloy

The microstructures and room temperature fracture toughness of directionally solidified NiAl-xCr-6Mo (x = 28, 32 and 36 at%) alloys were investigated. Fully eutectic microstructure could be obtained in the alloys over a wide composition range. High temperature gradient could increase the planar/cellular transition rate and expand the eutectic coupled growth zone. The volume fraction of Cr(Mo) strengthening phase increased with the increasing content of Cr, accordingly, the fracture toughness of NiAl–Cr(Mo) alloys also gradually increased. The fracture toughness of 26.15 MPa m^1/2 was obtained in the NiAl-36Cr-6Mo hypereutectic alloy solidified at withdrawal rate of 10 μm/s and temperature gradient of 600 K/cm, which is the highest value in the NiAl–Cr–Mo alloy system until now. Well-aligned microstructure was beneficial to the enhancement of the fracture toughness, while the existence of primary phase seriously deteriorated the toughness. All the directionally solidified NiAl–Cr(Mo) alloy failed as brittle quasi-cleavage fracture. Some toughening mechanisms, such as crack bridging, crack nucleation, crack blunting, crack deflection, interface debonding and shear ligament toughening as well as linkage of microcracks were observed. In addition, mobile dislocation generated from the interface also had significant influence on the toughness.     

Characterization of silicide phases formed during pack siliconizing coating on the Nb-1Zr-0.1C alloy

The present paper describes the morphology, chemistry and crystallography of the phases observed in the silicide coatings produced by pack cementation technique on Nb based alloys. Cross-sectional microstructures examined by transmission electron microscopy and scanning electron microscopy techniques have shown that the coating has two silicide layers: NbSi₂ and Nb₅Si₃. NbSi₂ formed at the surface of the sample and Nb₅Si₃ formed in between the substrate (Nb alloy) and NbSi₂ coating layer. Electron diffraction analyses revealed that NbSi₂ has hexagonal crystal structure with lattice parameters as a = 0.48 nm and c = 0.66 nm and Nb₅Si₃ has tetragonal crystal structure with lattice parameters as a = 0.65 nm and c = 1.19 nm. Nb₅Si₃ showed fine equiaxed grains, whereas, NbSi₂ exhibited duplex morphology having columnar grain morphology near to the Nb₅Si₃ layer and large equiaxed grains at the surface of the coating sample. The presence of duplex morphology was explained by estimating diffusion of various species and it was shown that columnar morphology of grains could be attributed to outward diffusion of Nb and equiaxed grains to inward diffusion of Si. In the case of Nb₅Si₃, growth takes place due to single element Si diffusion, leading to development of single equiaxed grain morphology of the Nb₅Si₃ phase.     

Influence of non-reactive particles on the microstructure of NiAl and NiAl–ZrO2 processed by thermal explosion

Nickel aluminide intermetallic alloy and NiAl–ZrO₂ composites were synthesized in a hot press by sintering reaction and thermal explosion (or Self-propagating High temperature Synthesis, SHS). The addition of a post-SHS heat treatment allows a control of the microstructure and an enhancement of the mechanical characteristics. Thus, NiAl properties processed by self-combustion are above those obtained by reactive sintering (RS). For all these syntheses, the role played by the non-reactive particles is determining. Indeed, the product granulometry is a function of the diluent size distribution since this latter acts as nucleation sites during the reactive processes. These particles can also enhance mechanical properties by specific reinforcement mechanisms and exercise an influence on SHS reaction parameters by controlling its reactivity and the thermal exchanges during self-combustion.     

Glass–ceramic coatings on titanium alloys for high temperature oxidation protection: Oxidation kinetics and microstructure

A glass–ceramic coating is applied on Ti–6Al–4V alloy for oxidation protection at 800 °C. Its dynamic oxidation and microstructure evolution are investigated. The titanium alloy substrate is effectively protected by the glass–ceramic coating, of which the oxidation develops at constant rate. The linear relationship of oxidation is deduced dm/dt = Dρ(C₁ − C₂)/(bC′), and the diffusion coefficient of oxygen at 800 °C in glass is obtained. Oxygen diffusion through glass coating is the controlling step. After the initial firing, silicide interlayer forms between the glass coating and titanium alloy substrate, where the ratio of Ti/Si decreases after oxidation due to Si diffusion and Ti consumption.     

High temperature oxidation of AZ91D magnesium alloy granule during in-situ melting

Oxidation behaviour of AZ91D was investigated by heating the alloy granules in a ceramic mould between 650 and 800 °C, for 30 and 60 min. The granules failed to melt in unprotected environment even when the temperature was increased to 800 °C. Raising the temperature increased the oxides thickness linearly, however, oxidation enhanced beyond 750 °C with severe mould–metal reaction and selective oxidation. Heating duration showed more pronounced effect on oxide formation compared to heating temperature. MgO was found to be the dominant compound in oxidation products. Aluminium participated during severe oxidation or combustion to some extent whilst no zinc oxide was detected.     

High-temperature oxidation behavior of minor Hf doped NiAl alloy in dry and humid atmospheres

Oxidation behavior of NiAl and 0.05 at.% Hf doped NiAl alloys were investigated at 1100 °C in dry and humid atmospheres. Hf doping significantly improved the cyclic oxidation resistance. Water vapour promoted the formation of voids at the scale/alloy interface and accelerated scale spallation. Also, water vapour had effect on the phase transformation from θ- to α-Al₂O₃ at the initial oxidation stage. In humid atmosphere, more Hf segregated at the scale/alloy interface to form oxide pegs. Pre-oxidation process in O₂ + Ar could compromise the effect of humid atmosphere on the oxidation kinetics of the NiAl alloys.     

Cyclic oxidation of high temperature coatings on new γ′-strengthened cobalt-based alloys

An emerging class of cobalt-based γ′-strengthened alloys promises higher temperature capabilities compared to current Ni-base superalloys commonly used in aerospace and power generation applications. As with Ni-base alloys, high temperature coatings that enhance environmental resistance are desirable. Single crystal samples of Co–9.2Al–9.0W and Co–7.8Al–7.8W–4.5Cr–2.0Ta (at.%) were coated with vapour phase nickel aluminide and MCrAlY. Samples were subjected to cyclic oxidation at 1100 °C with 300–450 1-h cycles. Compared to NiAl-based coatings, the MCrAlY coatings exhibited superior adherence and an interdiffusion zone free of detrimental intermetallic phases. Evolution of microstructure during cycling is discussed with reference to the available thermodynamic data.     

The oxidation of nanocrystalline Ni3Al fabricated by mechanical alloying and spark plasma sintering

Nanocrystalline Ni₃Al was fabricated through mechanical alloying of elemental powders and spark plasma sintering. The nanocrystalline Ni₃Al has a nearly full density after being sintered at 1223 K for 10 min under a pressure of 65 MPa. Isothermal and cyclic oxidations of nanocrystalline Ni₃Al were tested at 1173–1373 K with intervals of 100 K. The results indicate that nanocrystalline Ni₃Al exhibits excellent isothermal and cyclical oxidation resistance. The oxide scales consist primarily of dense and continuous -Al₂O₃. The grain refinement is beneficial for improving the oxidation resistance of Ni₃Al by providing more nucleation centers for the Al₂O₃ formation, promoting the selective formation of Al₂O₃ and improving the adhesion of oxide scales to the matrix.