Interfacial Reaction Between Nickel-Based Superalloy K417G and Oxide Refractories

doi:10.11900/0412.1961.2021.00048

Acta Metall Sin

2022, Vol. 58

Issue (7): 868-882 DOI: 10.11900/0412.1961.2021.00048

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Interfacial Reaction Between Nickel-Based Superalloy K417G and Oxide Refractories

SONG Qingzhong¹^,², QIAN Kun¹^,³, SHU Lei¹^,³, CHEN Bo¹^,³(

), MA Yingche¹^,³, LIU Kui¹^,³

^1.Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
^2.School of Metallurgy, Northeastern University, Shenyang 110819, China
^3.Shi -changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

Cite this article:

SONG Qingzhong, QIAN Kun, SHU Lei, CHEN Bo, MA Yingche, LIU Kui. Interfacial Reaction Between Nickel-Based Superalloy K417G and Oxide Refractories. Acta Metall Sin, 2022, 58(7): 868-882.

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Abstract

High-performance nickel-based superalloys are highly desired in the aerospace industry. A drawback of vacuum induction melting for processing nickel-based superalloys is that oxide refractories contaminate the molten alloy through crucible-melt interaction. Therefore, crucibles used for producing nickel-based superalloys should be carefully selected to avoid melt contamination. In this study, the interfacial reaction between a molten nickel-based superalloy (K417G) and various oxide refractories, including Al₂O₃, CaO, MgO, ZrO₂ + 12%Y₂O₃ (mass fraction) (Y-PSZ), ZrO₂ + 20%CaO (CSZ), and Y₂O₃, formed by cold isostatic pressing was investigated at 1600^oC by XRD, SEM, and EDS. The effects of the oxide crucibles on the impurity contents of K417G were also evaluated. The results show that physical erosion is the primary mechanism of the interaction between Al₂O₃ crucibles and alloy melt. The readily detached Al₂O₃ particles formed inclusions in the alloy. The Ca₃Al₂O₆ liquid phase generated at the melt-crucible interface promoted wettability between the alloy and CaO crucible, resulting in a high adhesion at the interface. The reaction of the MgO crucible with Al in the alloy resulted in the formation of MgAl₂O₄ at the melt-crucible interface, which subsequently entered the alloy to form inclusions. Al₂O₃ was generated at the Y-PSZ-crucible-alloy interface. However, there was no corrosion of Al₂O₃in the Y-PSZ crucible, indicating the crucible exhibits excellent corrosion resistance to Al₂O₃ slags. The interaction between the CSZ crucible and alloy melt generated a CaAl₂O₄ liquid phase, making the crucible unstable to dissolve into the alloy. An Al₂Y₄O₉ reaction layer is mainly formed at the Y₂O₃-crucible-alloy interface. The dissolution of Y₂O₃ into the alloy melt was high compared to that of other oxide refractories. The melt-crucible interaction also significantly affected the oxygen content of K417G. The oxygen concentration of the alloy fused by CaO, Y₂O₃, and Y-PSZ crucibles did not increase, whereas that of the alloy melted in CSZ, MgO, and Al₂O₃ crucibles increased from 0.0007% to 0.0011%, 0.0034%, and 0.0135%, respectively.

Key words: interfacial reaction K417G refractory Al₂O₃ CaO MgO ZrO₂ Y₂O₃

Received: 26 January 2021

ZTFLH:

TG146.1

About author: CHEN Bo, professor, Tel: (024)83971986, E-mail: bchen@imr.ac.cn

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	Kui LIU

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https://www.ams.org.cn/EN/10.11900/0412.1961.2021.00048 OR https://www.ams.org.cn/EN/Y2022/V58/I7/868

Raw material	Purity / (mass fraction, %)
Al₂O₃	≥ 99.61, MgO ≤ 0.10, SiO₂ ≤ 0.13, CaO ≤ 0.16, Fe₂O₃ ≤ 0.002, TiO₂ ≤ 0.01, Na₂O ≤ 0.03
CaO	≥ 96.78, MgO ≤ 0.53, Al₂O₃ ≤ 0.20, SiO₂ ≤ 0.05, TFe ≤ 0.01, TiO₂ ≤ 0.014, S ≤ 0.001, Loss ≤ 2.01
MgO	≥ 98.5, Fe ≤ 0.005, Ba ≤ 0.003, Cl^- ≤ 0.07, SO $4 2 -$ ≤0.05, Pb ≤ 0.005, Loss ≤ 4.5,
Y₂O₃	≥ 99.99, Loss ≤ 0.01
ZrO₂	≥ 99.0, Fe₂O₃ ≤ 0.005, MgO ≤ 0.05, CaO ≤ 0.05, TiO₂ ≤ 0.005, SiO₂ ≤ 0.01, Loss ≤ 1

Table 1 Purities of raw materials for manufacturing oxide crucibles

Table 2 Process parameters forming oxide crucibles, apparent porosity, and bulk density

Fig.1 Schematic diagram of experiment equipment

Fig.2 XRD spectra of various oxide crucibles after sintering
(a) Al₂O₃ and MgO
(b) CaO and Y₂O₃
(c) Y-PSZ and CSZ (m—monoclinic, t—tetragonal, c—cubic)

Fig.3 Macromorphology of nickel-based superalloy K417G smelted by Al₂O₃ crucible

Fig.4 Al₂O₃ inclusions flowed at the liquid surface

Fig.5 SEM image (a) and EDS mappings (b-f) of the interface between Al₂O₃ crucible and nickel-based superalloy K417G

Table 3 Chemical compositions of the interface between Al₂O₃ crucible and K417G alloy in Fig.5a by EDS analysis

Fig.6 SEM image (a) and EDS mappings (b-f) of the interface between CaO crucible and nickel-based superalloy K417G

Table 4 Chemical compositions of the interface between CaO crucible and K417G alloy in Fig.6d by EDS analysis

Fig.7 Macromorphology of nickel-based superalloy K417G smelted by CaO crucible

Fig.8 SEM image (a) and EDS mappings (b-f) of the interface between MgO crucible and nickel-based superalloy K417G

Table 5 Chemical compositions of the interface between MgO crucible and K417G alloy in Fig.8a by EDS analysis

Fig.9 MgAl₂O₄ inclusions flowed at the liquid surface

Fig.10 SEM image (a) and EDS mappings (b-f) of the interface between Y-PSZ crucible and nickel-based superalloy K417G

Table 6 Chemical composition of the interface between Y-PSZ crucible and K417G alloy in Fig.10a by EDS analysis

Fig.11 Al₂O₃ inclusions flowed at the liquid surface smelted by Y-PSZ crucible

Fig.12 SEM images (a) and EDS mappings (b-f) of the interface between CSZ crucible and nickel-based superalloy K417G

Table 7 Chemical composition of the interface between CSZ crucible and K417G alloy by EDS analysis (See points in Figs.12-14)

Fig.13 Backscattered electron (BSE) image (a) and EDS mappings (b-d) of CSZ crucible after smelting nickel-based superalloy K417G

Fig.14 BSE image of original micromorphology of CSZ crucible

Fig.15 Macromorphology of nickel-based superalloy K417G smelted by CSZ crucible

Fig.16 SEM image (a) and EDS mappings (b-f) of the interface between Y₂O₃ crucible and nickel-based superalloy K417G

Fig.17 BSE images of interface between Y₂O₃ crucible and K417G alloy (a) and K417G alloy (b) smelted by Y₂O₃ crucible (Insets are EDS mappings of segregation regions of Y inside K417G alloy)

Table 8 Chemical compositions of the interface between Y₂O₃ crucible and K417G alloy in Fig.17a by EDS analysis

Table 9 Impurity element contents of nickel-based superalloy K417G after melting

Fig.18 Relationships between the formation Gibbs free energy (ΔG^θ ) of various oxide materials and temperatures

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