Structure and elevated temperature properties of carbon-free ferritic alloys strengthened by a laves phase

A Laves phase, Fe₂Ta, was utilized to obtain good elevated temperature properties in a carbon-free iron alloy containing 1 at. pct Ta and 7 at. pct Cr. Room temperature embrittlement resulting from the precipitation of the Laves phase at grain boundaries was overcome by spheroidizing the precipitate. This was accomplished by thermally cycling the alloys through the α→γ transformation. The short-time yield strength of the alloys decreased very slowly with increase in test temperature up to 600°C, but above this temperature, the strength decreased rapidly. Results of constant load creep and stress rupture tests conducted at several temperatures and stresses indicated that the rupture and creep strengths of spheroidized 1 Ta-7 Cr alloy were higher than those of several commercial steels containing chromium and/or molybdenum carbides but lower than those of steels containing substantial amounts of tungsten and vanadium. When molybdenum was added to the base Fe-Ta-Cr alloy, the rupture and creep strengths were considerably increased. M. Dilip Bhandarkar, formerly with Lawrence Berkeley Laboratory.     

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).     

The influence of cobalt,tantalum, and tungsten on the elevated temperature mechanical properties of single crystal nickel-base superalloys

The influence of composition on the tensile and creep strength of [001] oriented nickel-base superalloy single crystals at temperatures near 1000 °C was investigated. Cobalt, tantalum, and tungsten concentrations were varied according to a matrix of compositions based on the single crystal version of MAR-M247.* For alloys with the baseline refractory metal level of 3 wt pct Ta and 10 wt pct W, decreases in Co level from 10 to 0 wt pct resulted in increased tensile and creep strength. Substitution of 2 wt pct W for 3 wt pct Ta resulted in decreased creep life at high stresses, but improved life at low stresses. Substitution of Ni for Ta caused large reductions in tensile strength and creep resistance, and corresponding increases in ductility. For these alloys with low Ta plus W totals, strength was independent of Co level. The effects of composition on properties were related to the microstructural features of the alloys. In general, high creep strength was associated with high levels ofγ′ volume fraction,γ-γ′ lattice mismatch, and solid solution hardening.     

Heat treatment behavior and tensile properties of Cr−W steels

Ferritic steels containing Cr, W, and V are being developed for fusion reactor applications. These steels would be alternatives to the Cr−Mo steels that are being considered for structural components. Eight experimental steels were produced. Chromium concentrations of 2.25, 5, 9, and 12 pct were used. Steels with these chromium compositions and with 2 pct W and 0.25 pct V were produced. To determine the effect of tungsten and vanadium, 2.25Cr steels were also produced with 2 pct W and no vanadium, and with 0.25 pct V and zero and 1 pct W. A 9Cr steel containing 2 pct W, 0.25 pct V, and 0.07 pct Ta was also studied. For all alloys, carbon was maintained at 0.1 pct. Tempering behavior of the steels was similar to that of the Cr−Mo steels being considered. Tensile studies indicated that the 2.25Cr−2W−0.25V and 9Cr−2W−0.25V−0.07Ta steels had the highest strengths with properties similar to those of the 9Cr−1MoVNb and 12Cr−1MoVW steels, which are the strongest of the Cr−Mo steels of interest.     

Effect of composition on the properties of strain-transformable β titanium alloys

A number of metastableβ titanium alloys were examined to determine the effects of composition on strain-transformation behavior and precipitation hardening response. Maximum ductility as solution heat treated was observed in alloys slightly richer in alloy content than the minimum alloy content required to retain an all-β microstructure on quenching. Such materials transformed to a martensitic structure upon straining and, as a result of strain transformation, developed room temperature ductility exceeding that found in unalloyed titanium. Uniform elongation of 35 to 45 pct was observed in a number of compositions of this type containing major additions of Mo, V, Cr, or Mn. Auxiliary alloy additions of Sn, Al, or Zr, or ternary alloying with molybdenum were necessary to preventω embrittlement during quenching in alloys containing V, Cr, or Mn. Alloying with Fe, Cu, Co, or Ni resulted in low ductility as solution heat treated, but it is probable that optimum amounts of these additions were not studied in this investigation. Oxygen above about 1200 ppm also had a detrimental effect on ductility. All alloys studied showed precipitation hardening when heat treated in the 800° to 1100°F range. Tensile strengths of 170 to 190 ksi were readily attainable in most alloy systems. Ductility as precipitation hardened appeared to be higher in alloys containing at least 6 pct Mo or V than in other alloys studied.     

Creep and fracture of a Laves phase strengthened ferritic alloy

The microstructural changes which occurred during creep were examined in a carbon-free ferritic alloy containing 1 at. pct Ta and 7 at. pct Cr. The alloy derived its creep resistance from a uniform dispersion of almost spherical particles of the Laves phase Fe₂Ta in a bcc matrix. There was a lath-like substructure in this alloy, with dislocation tangles and subgrains within the laths. Partial recovery during creep led to the formation of a regular subgrain structure. The Laves phase particles prevented total recovery by pinning individual dislocations and subgrain boundaries. The apparent activation energy for creep, the estimated stress sensitivity of minimum creep rate, and the substructural features observed in crept specimens suggested that creep deformation of the alloy occurred by two or more independent processes. Fracture under creep conditions was initiated by void formation at precipitate-matrix interfaces. Intergranular void formation played an important role in the fracture of creep specimens tested at 1200°F (649°C), but not at lower temperatures.     

Creep and fracture of a laves phase strengthened ferritic alloy

The microstructural changes which occurred during creep were examined in a carbon-free ferritic alloy containing 1 at. pct Ta and 7 at. pct Cr. The alloy derived its creep resistance from a uniform dispersion of almost spherical particles of the Laves phase Fe₂Ta in a bee matrix. There was a lath-like substructure in this alloy, with dislocation tangles and subgrains within the laths. Partial recovery during creep led to the formation of a regular subgrain structure. The Laves phase particles prevented total recovery by pinning individual dislocations and subgrain boundaries. The apparent activation energy for creep, the estimated stress sensitivity of minimum creep rate, and the sub-structural features observed in crept specimens suggested that creep deformation of the alloy occurred by two or more independent processes. Fracture under creep conditions was initiated by void formation at precipitate-matrix interfaces. Intergranular void formation played an important role in the fracture of creep specimens tested at 1200°F (649°C), but not at lower temperatures. M. Dilip Bhandarkar was formerly associated.     

Structure and properties of corrosion and wear resistant Cr-Mn-N steels

Steels containing about 12 pct Cr, 10 pct Mn, and 0.2 pct N have been shown to have an unstable austenitic microstructure and have good ductility, extreme work hardening, high fracture strength, excellent toughness, good wear resistance, and moderate corrosion resistance. A series of alloys containing 9.5 to 12.8 pct Cr, 5.0 to 10.4 pct Mn, 0.16 to 0.32 pct N, 0.05 pct C, and residual elements typical of stainless steels was investigated by microstructural examination and mechanical, abrasion, and corrosion testing. Microstructures ranged from martensite to unstable austenite. The unstable austenitic steels transformed to α martensite on deformation and displayed very high work hardening, exceeding that of Hadfield’s manganese steels. Fracture strengths similar to high carbon martensitic stainless steels were obtained while ductility and toughness values were high, similar to austenitic stainless steels. Resistance to abrasive wear exceeded that of commercial abrasion resistant steels and other stainless steels. Corrosion resistance was similar to that of other 12 pct Cr steels. Properties were not much affected by minor compositional variations or rolled-in nitrogen porosity. In 12 pct Cr-10 pct Mn alloys, ingot porosity was avoided when nitrogen levels were below 0.19 pet, and austenitic microstructures were obtained when nitrogen levels exceeded 0.14 pct.     

Effects of composition and microstructure on fatigue of γ/γ′-δ type eutectic alloys

Room temperature tension-tension fatigue tests were performed on two lamellar γ/γ′-δ alloys, one with 0 pct Cr and one with 6 pct Cr. The 6 pct Cr alloy was solidified at 3 cmJh while the 0 pct Cr alloy was solidified at 3 cm/h and 5.7 cm/h. Fatigue testing was done on both alloys in the as-directionally solidified condition and on the 0 pct Cr alloy after heat treatment. Increasing the growth speed of the 0 pct Cr alloy increased the fatigue life of the material at stresses above the 10⁷ cycle fatigue limit. Partial solution treating and aging of the 0 pct Cr alloy,R = 3 cm/h, increased the fatigue life relative to the as-directionally solidified material at high stresses, to the same extent as increasing the growth speed. Full solution treatment and aging of the 0 pct Cr alloy,R = 5.7 cm/ h, caused a reduction in the fatigue life relative to the as-directionally solidified material. Fatigue cracking tended to be faceted in the 6 pct Cr alloy as opposed to the more ductile failure of the 0 pct Cr alloy. Microstructural perfection, grain size and shape, interlamellar spacing, longitudinal cracking, and longitudinal and transverse ductility all are believed to have influenced the fatigue resistance of the alloys.     

Creep Behavior and Degradation of Subgrain Structures Pinned by Nanoscale Precipitates in Strength-Enhanced 5 to 12 Pct Cr Ferritic Steels

Creep behavior and degradation of subgrain structures and precipitates of Gr. 122 type xCr-2W-0.4Mo-1Cu-VNb (x = 5, 7, 9, 10.5, and 12 pct) steels were evaluated during short-term and long-term static aging and creep with regard to the Cr content of steel. Creep rupture life increased from 5 to 12 pct Cr in the short-term creep region, whereas in the long-term creep region, it increased up to 9 pct Cr and then decreased with the addition of Cr from 9 to 12 pct. Behavior of creep rupture life was attributed to the size of elongated subgrains. In the short-term creep region, subgrain size decreased from 5 to 12 pct Cr, corresponding to the longer creep strength. However, in the long-term creep region after 10⁴ hours, subgrain size increased up to 9 pct Cr and then decreased from 9 to 12 pct, corresponding to the behavior of creep rupture life. M₂₃C₆ and MX precipitates had the highest number fraction among all of the precipitates present in the studied steels. Cr concentration dependence of spacing of M₂₃C₆ and MX precipitates exhibited a V-like shape during short-term as well as long-term aging at 923 K (650  °C), and the minimum spacing of precipitates belonged to 9 pct Cr steel, corresponding to the lowest recovery speed of subgrain structures. In the short-term creep region, subgrain coarsening during creep was controlled by strain and proceeded slower with the addition of Cr, whereas in long-term creep region, subgrain coarsening was controlled by the stability of precipitates rather than due to the creep plastic deformation and took place faster from 9 to 12 pct and 9 to 5 pct Cr. However, M₂₃C₆ precipitates played a more important role than MX precipitates in the control of subgrain coarsening, and there was a closer correlation between spacing of M₂₃C₆ precipitates and subgrain size during static aging and long-term creep region.     

Influence of silicon and phosphorous on the mechanical properties of both ferrite and dual-phase steels

A study has been made of the influence of up to 2 pct Si and 0.42 pct P upon the strength and ductility of ferrites over a wide grain size range; the grain size was varied fromd ^−1/2 mm^−1/2 = 4 to 14. Although the ductility decreased with increasing strength for all the alloys, the 2 pct Si alloy had the best combination of strength and ductility. The ferrites containing 2 pct Si and 0.2 pct P had greater uniform elongations than conventional HSLA steels at the same tensile strength; it is thought that the ductility of the ferrites is enhanced by the presence of Si while the ductility of conventional HSLA steels is reduced by the presence of carbide precipitates. With the theory for a composite of two ductile phases and the results for the fine-grained alloyed ferrites, the change in uniform elongation as a function of tensile strength was predicted for dual-phase (martensite plus ferrite) steels. Good agreement was found between the prediction and experimental results for dual-phase steels containing up to 0.2 pct P or 2 pct Si; the 2 pct Si alloy had the best combination of strength and ductility of all dual-phase steels so far reported. This study again emphasizes the importance of the high strength, high ductility ferrite in controlling the properties of dual-phase steels.     

Work strengthening by a deformation-induced phase transformation in “MP alloys”

Work strengthening and microstructure were investigated for a class of alloys, designated “MP Alloys”, containing 20 pct Cr, 10 pct Mo, and the remainder cobalt and nickel in proportions ranging from 60Co∶10Ni to 30Co∶40Ni. These alloys, in the fully annealed, homogenized condition, have a fcc structure with yield strengths ranging from about 45 to 60 ksi. Deformation at room temperature rapidly increases the yield strength of the alloys to about 250 ksi. Structural analyses by X-ray and electron diffraction techniques indicate that this marked increase in strength is associated with a deformation-induced martensitic transformation forming a network of extremely thin hcp platelets within the fcc grains. The nature of this martensitic transformation was studied as a function of alloy composition, deformation temperature, and structural variables, such as the platelet size, thec/a ratio of the hcp phase, and twinning.     

Microstructure and mechanical behavior of Cr-Cr2Hfin situ intermetallic composites

A detailed investigation of the effects of microstructural changes on the mechanical behavior of twoin situ intermetallic composites with Cr and Cr₂Hf phases in the Cr-Hf system was performed. The nominal compositions (at. pct) of the alloys were Cr-5.6Hf (hypoeutectic) and Cr-13Hf (eutectic). The study included evaluations of strength, ductility, and fracture toughness as a function of temperature and creep behavior. Two microstructures in each alloy were obtained by heat treatments at 1250 ‡C (fine microstructure) and 1500 ‡C (coarse microstructure). A decrease in elastic strength (stress at the onset of inelastic response in the load-deflection curve) with the coarsening of the microstructures was noted for both alloys below 1000 ‡C. The Cr-13Hf alloy retained strength to a higher test temperature, relative to Cr-5.6Hf alloy, under both microstructural conditions. The alloys showed no evidence of ductility at room temperature. However, in the coarse microstructure of the Cr-5.6Hf alloy, the primary Cr exhibited ductility at and above 200 ‡C; ductility in primary Cr could be seen only at and above 1000 ‡C for the fine microstructure. In other words, the temperature at which ductility was first observed decreased from about 1000 ‡C to about 200 ‡C due to high-temperature heat treatment in this alloy. Both microstructures of Cr-5.6Hf alloy showed a significant increase in fracture toughness with increasing test temperature. However, the increases in fracture toughness with temperature for the Cr-13Hf alloy microstructures were relatively small. Both alloys showed about four orders of magnitude reduction in steady-state creep rates relative to pure Cr at 1200 ‡C. The results are analyzed in the light of deformation characteristics and fracture micromechanisms. The effects of microstructural factors, such as the size and continuity of phases, solubility levels of Hf as well as interstitial elements in Cr, on the observed mechanical behavior are discussed. Formerly Research Scientist, Materials and Processes, UES, Inc.     

Short-range order effects on the tensile behavior of a nickel-base alloy

A nickel base weld filler metal alloy with nominal composition of 67 pct Ni, 20 pct Cr, 3 pct Mn, 3 pct Fe, and 2.5 pct Nb (Cb) is used to make austenitic-ferritic dissimilar metal joints. Tensile properties were determined for this alloy over the range 25 to 732°C at strain-rates of 3×10⁻⁶ and 3×10⁻⁴/s. Above about 450°C, both the yield strength and the ultimate tensile strength in the low strain-rate tests showed significant increases over the strengths at the higher strain-rate. The enhanced values for the yield strength persisted to the highest test temperature (732°C), whereas the ultimate tensile strength for the low strain-rate fell below the curve for the higher strain-rate at about 600°C. Above 600°C, the ultimate tensile strength dropped off rapidly and at 677°C approached the yield strength (i.e., the uniform elongation dropped to less than 1 pct). The strain-rate effects have been attributed to “K-state” formation, an effect that investigators have attributed to short range order in other Ni−Cr base alloys.     

Alloying mechanism of beta stabilizers in a TiAl alloy

The effects of beta stabilizers such as Fe, Cr, V, and Nb on the microstructures and phase constituents of Ti₅₂Al₄₈-xM (x=0, 1.0, 2.0, 4.0, or 6.0 at. pct and M=Fe, Cr, V, and Nb) alloys were studied. The dependence of the tensile properties and creep resistance of TiAl on the alloying elements, especially the formation of B2 phase, was investigated. Fe is the strongest B2 stabilizer, Cr is second, V is an intermediate stabilizer, and Nb is the weakest stabilizer. The composition partitioning of Fe, Cr, V, and Nb in the γ phase is affected by the formation of B2 phase. The peaks of the tensile strengths and creep rupture life of Ti₅₂Al₄₈-xM generally occur at the maximum solid solution of these elements in the γ phase, which is just before the formation of B2 phase. Ti₅₂Al₄₈-0.5Fe shows an attractive elongation of 2.5 pct at room temperature, and the Ti₅₂Al₄₈-1V, Ti₅₂Al₄₈-Cr, and Ti₅₂Al₄₈-2Nb alloys have about 1.1 to 1.3 pct elongation at room temperature. The increase of tensile strengths and creep resistance with increasing Fe, Cr, V, and Nb contents is chiefly attributed to the solid-solution strengthening of these elements in the γ phase. The appearance of B2 phase deteriorates the creep resistance, room-temperature strengths, and ductility. With respect to the maximum solid-solution strengthening, an empirical equation of the Cr equivalent [Cr] is suggested as follows: [Cr]=Cr+Mn+3/5V+3/8Nb+3/2 (W+Mo)+3Fe=1.5 to 3.0. The solid-solution strengthening mechanism of Fe, Cr, V, and Nb at room temperature arises from the increase of the Ti 3s and Al 2s binding energies in Ti-Ti and Al-Al bonds, and the retention of the strength and creep resistance at elevated temperatures in Ti₅₂Al₄₈-xM is mainly attributed to the increase of the Ti 3s and Al 2s binding energies in Ti-Al bonds in γ phase. The decrease of the Ti 3p and Al 2p binding energies in Ti-Ti, Ti-Al, and Al-Al bonds benefits the ductility of TiAl.     

The microstructure of chromium-tungsten steels

Chromium-tungsten steels are being developed to replace the Cr-Mo steels for fusion-reactor applications. Eight experimental steels were produced and examined by optical and electron microscopy. Chromium concentrations of 2.25, 5, 9 and 12 pct were used. Steels with these chromium compositions and with 2 pct W and 0.25 pct V were produced. To determine the effect of tungsten and vanadium, three other 2.25Cr steels were produced as follows: an alloy with 2 pct W and 0 pct V and alloys with 0 and 1 pct W and 0.25 pct V. A 9Cr steel containing 2 pct W, 0.25 pct V, and 0.07 pct Ta also was studied. For all alloys, carbon was maintained at 0.1 pct. Two pct tungsten was required in the 2.25Cr steels to produce 100 pct bainite (no polygonal ferrite). The 5Cr and 9Cr steels were 100 pct martensite, but the 12Cr steel contained about 25 pct delta-ferrite. Precipitate morphology and precipitate types varied, depending on the chromium content. For the 2.25Cr steels, M₃C and M₇C₃ were the primary precipitates; for the 9Cr and 12Cr steels, M₂₃C₆ was the primary precipitate. The 5Cr steel contained M₇C₃ and M₂₃C₆. All of the steels with vanadium also contained MC.     

Elevated temperature compressive properties of Zr-modified NiAl

Small Zr additions are known to substantially affect the deformation behavior and strength of po-lycrystalline NiAl, yet little information is currently available regarding the high-temperature prop-erties of such alloys. Utilizing prealloyed powder technology, a series of four NiAl alloys have been produced containing from 0.05 to 0.7 at. pct Zr. The creep behavior of these alloys was characterized in compression between 1000 and 1400 K at strain rates ranging from ∼0.1 to 10^-9 s^-1. All the Zr-modified alloys were significantly stronger than binary NiAl under lower temperature and faster strain-rate conditions; however, the single-phase materials (Zr ≤ 0.1 at. pct) and binary NiAl had similar strengths at high temperatures and slow strain rates. The two-phase NiAl-Ni₂AlZr alloys containing 0.3 and 0.7 at. pct Zr had nearly identical strengths. While the two-phase alloys were stronger than the single-phase materials at all test conditions, the degree of microstructural damage in the two-phase alloys due to internal oxidation during testing appeared to increase with Zr level. Balancing the poor oxidation behavior with the consistent strength advantage of the two-phase alloys, it is concluded that optimum elevated-temperature properties could be obtained in Heusler-strength-ened NiAl containing between 0.1 and 0.3 at. pct Zr.     

Role of Microstructure and Temperature on the Tensile Fracture Behavior of Oxide Dispersion Strengthened 18Cr Ferritic Steel

The tensile fracture behavior of oxide dispersion strengthened 18Cr (ODS-18Cr) ferritic steels milled for varying times was studied along with the oxide-free 18Cr steel (NODS) at 25, 200, 400, 600, and 800 °C. At all the test temperatures, the strengths of ODS–18Cr steels increased and total elongation decreased with the duration of milling time. Oxide dispersed 18Cr steel with optimum milling exhibited enhanced yield strength of 156 pct at room temperature and 300 pct at 800 °C when compared to oxide-free 18Cr steel. The ductility values of ODS-18Cr steels are in the range 20 to 35 pct for a temperature range 25 to 800 °C, whereas NODS alloy exhibited higher ductility of 37 to 82 pct. The enhanced strength of ODS steels when compared to oxide-free steel is due to the development of ultrafine grained structure along with nanosized dispersion of complex oxide particles. While the pre-necking elongation decreased with increasing temperature and milling time, post-necking elongation showed no change with the test temperature. Fractographic examination of both ODS and NODS 18Cr steel fractured tensile samples, revealed that the failure was in ductile fracture mode with distinct neck and shear lip formation for all milling times and at all test temperatures. The fracture mechanism is in general followed the sequence; microvoid nucleation at second phase particles, void growth and coalescence. The quantified dimple sizes and numbers per unit area were found to be in linear relation with the size and number density of dispersoids. It is clearly evident that even nanosized dispersoids acted as sites for microvoid nucleation at larger strains and assisted in dimple rupture.