High-Temperature Oxidation Behavior of Spark Plasma Sintered Ni20Cr-xAl Alloys

doi:10.11900/0412.1961.2022.00240

Acta Metall Sin

2024, Vol. 60

Issue (4): 485-494 DOI: 10.11900/0412.1961.2022.00240

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High-Temperature Oxidation Behavior of Spark Plasma Sintered Ni20Cr-xAl Alloys

LIU Chengji, SUN Wenyao(

), CHEN Minghui, WANG Fuhui

Shenyang National Laboratory for Materials Science, Northeastern University, Shenyang 110819, China

Cite this article:

LIU Chengji, SUN Wenyao, CHEN Minghui, WANG Fuhui. High-Temperature Oxidation Behavior of Spark Plasma Sintered Ni20Cr-xAl Alloys. Acta Metall Sin, 2024, 60(4): 485-494.

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Abstract

As a high-performance structural material, nickel-based superalloy has excellent comprehensive properties, such as high-temperature mechanical properties, thermal stability, and corrosion resistance. It is widely used in hot-end parts, including the combustion chamber, turbine blades, and turbine disks, among others. Due to severe working environments, oxidation has become a major life-limiting factor for the nickel-based superalloy. However, the high-temperature oxidation behavior of a superalloy is complex, related to many factors, such as chemical composition and preparation technology. Many advances have been achieved through improving alloy compositions to meet the anti-oxidation requirements, and others have been accomplished using major innovations in processing. As a new powder metallurgy technology, spark plasma sintering (SPS) has the advantages of a fast heating rate, low sintering temperature, and short sintering time. However, there are few studies on the oxidation behavior of alloys prepared by this technology. In this study, Ni20Cr-xAl alloys with Al content (mass fraction) of 1.5%, 3.0%, and 5.0% were prepared by mechanical alloying and SPS. Oxidation kinetics, XRD, SEM, and TEM were used to compare and investigate the isothermal oxidation behaviors of the SPSed and the as-cast alloys with the same composition in air at 900^oC. Results indicate that the SPSed alloys have uniform microstructures and fine grains, and abundant grain boundaries significantly accelerate the diffusion of elements. When the Al content is 1.5%, severe internal oxidation of Al occurs, and a Cr₂O₃ scale containing large pores and cracks is formed due to rapid external oxidation of Cr. Al₂O₃ particles dispersed in the alloy serve as nucleation sites for the exterior Al₂O₃ scale and have a pinning effect. However, when the Al content reaches 3.0% and 5.0%, a protective, continuous, and dense α-Al₂O₃ thin scale emerges. Therefore, both alloys display excellent oxidation resistance, the oxidation weight gain is 0.25 and 0.20 mg/cm², respectively, and the corresponding oxidation rate is 1.06 × 10^-7 and 4.92 × 10^-8 mg²/(cm⁴·s). Internal oxidation occurs in all the as-cast alloys, and no continuous external Al₂O₃ scale can be formed. The main component of the oxide scales is porous Cr₂O₃, which results in high oxidation rates and crack and spallation of the oxide scales.

Key words: superalloy fine-grain structure high-temperature oxidation spark plasma sintering

Received: 12 May 2022

ZTFLH:

TG178

Fund: National Natural Science Foundation of China(51871051);China Postdoctoral Science Foundation(2022M720678)

Corresponding Authors: SUN Wenyao, associate professor, Tel: 17824032549, E-mail: sunwenyao@mail.neu.edu.cn

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	LIU Chengji
	SUN Wenyao
	CHEN Minghui
	WANG Fuhui

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https://www.ams.org.cn/EN/10.11900/0412.1961.2022.00240 OR https://www.ams.org.cn/EN/Y2024/V60/I4/485

Fig.1 SEM images of the Ni20Cr-xAl alloys with x = 1.5 (a), x = 3.0 (b), and x = 5.0 (c) prepared by spark plasma sintering (SPS)

Fig.2 XRD spactra of the SPSed Ni20Cr-xAl alloys

Fig.3 EBSD images (a-c) and grain size distributions (d-f) of the SPSed Ni20Cr-xAl alloys with x = 1.5 (a, d), x = 3.0 (b, e), and x = 5.0 (c, f)

Fig.4 TEM image and elemental mappings of the SPSed Ni20Cr-3.0Al alloy

Fig.5 Isothermal oxidation kinetics of the as-cast alloys and SPSed alloys after oxidation at 900^oC for 100 h
(a) Δw vs t (Δw—mass change, t—oxidation time)
(b) (Δw)²vs t

Table 1 Δw and oxidation rate constant (k_p) of the as-cast and SPSed alloys after oxidation at 900^oC for 100 h

Fig.6 XRD spactra of the as-cast and SPSed Ni20Cr-xAl alloys after oxidation at 900^oC for 100 h

Fig.7 Surface SEM images of the as-cast (a-c) and SPSed (d-f) Ni20Cr-xAl alloys with x = 1.5 (a, d), x = 3.0 (b, e), and x = 5.0 (c, f) after oxidation at 900^oC for 20 h

Fig.8 Surface SEM images of the as-cast (a-c) and SPSed (d-f) Ni20Cr-xAl alloys with x = 1.5 (a, d), x = 3.0 (b, e), and x = 5.0 (c, f) after oxidation at 900^oC for 100 h

Fig.9 Low and high (insets) magnified cross-sectional SEM images and corresponding element mapping of the as-cast Ni20Cr-xAl alloys with x = 1.5 (a), x = 3.0 (b), and x = 5.0 (c) after oxidation at 900^oC for 100 h

Fig.10 Low and high (insets) magnified cross-sectional SEM images and corresponding element mapping of the SPSed Ni20Cr-xAl alloys with x = 1.5 (a), x = 3.0 (b), and x = 5.0 (c) after oxidation at 900^oC for 100 h

Fig.11 TEM image (a) of the oxide scale formed on SPSed Ni20Cr-5.0Al alloy after oxidation at 900^oC for 100 h, and selected area electron diffraction patterns of grains 1 (b) and 2 (c) in Fig.11a

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