Oxidation Behavior of a Low-Cost Third-Generation Ni-Based Single-Crystal Superalloy

doi:10.11900/0412.1961.2023.00275

Acta Metall Sin

2025, Vol. 61

Issue (7): 1049-1059 DOI: 10.11900/0412.1961.2023.00275

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Oxidation Behavior of a Low-Cost Third-Generation Ni-Based Single-Crystal Superalloy

LI Yongmei¹^,², TAN Zihao¹^,², WANG Xinguang²(

), TAO Xipeng², YANG Yanhong², LIU Jide², LIU Jinlai², LI Jinguo², ZHOU Yizhou², SUN Xiaofeng²(

)

1 School of Materials Science and Engineering, University of Science and Technology of China, Shenyang 110016, China
2 Shi -changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

Cite this article:

LI Yongmei, TAN Zihao, WANG Xinguang, TAO Xipeng, YANG Yanhong, LIU Jide, LIU Jinlai, LI Jinguo, ZHOU Yizhou, SUN Xiaofeng. Oxidation Behavior of a Low-Cost Third-Generation Ni-Based Single-Crystal Superalloy. Acta Metall Sin, 2025, 61(7): 1049-1059.

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Abstract

At present, the development of low-cost Ni-based single-crystal (SX) superalloys with excellent properties is urgently needed to address the increasing cost of advanced aero-engines. In this study, a novel low-cost, third-generation Ni-based SX superalloy containing 3%Re (mass fraction) was investigated to assess its oxidation behavior and γ′ phase degradation at 1120 ^oC. Results showed that during the first 5 h of oxidation, a continuous and uniform three-layer oxide film was formed on the surface of samples. Given the relatively thin oxide film, measured at approximately 5 μm, the experimental alloy followed sub-parabolic kinetics. Between 10 and 100 h of oxidation, the nucleation and propagation of cracks in the Al₂O₃ interlayer accelerated the spallation of protective oxide films. This event resulted in the increased oxidation of the matrix alloy, along with the formation of AlN and large areas in the oxidation reaction domain (ORD). These phenomena caused the transformation from sub-parabolic kinetics to linear kinetics. After 150 h of oxidation, a continuous and zigzagging Al₂O₃ layer was formed at the bottom of the ORD that could hinder the outward diffusion of alloy elements and the inward diffusion of oxygen. Consequently, the alloy gradually approached parabolic kinetics as the Al₂O₃ layer was thickened. In addition, the intense oxidation reaction on the surface accelerated the degradation of the γ′ phase and the precipitation of the topologically close pack phase near the surface. Therefore, the low bond strength between the surface oxide film and the alloy matrix primarily contributed to the deficiency of high-temperature oxidation resistance of this experimental alloy.

Key words: Ni-based single-crystal superalloy oxidation scale spallation kinetic behavior γ′ degradation

Received: 03 July 2023

ZTFLH:

TG132.32

Fund: Excellent Youth Foundation of Liaoning Province(2021-YQ-02);Middle-Aged and Youth Talents in Scientific and Technological Innovation Project of Shenyang(RC220440)

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	Articles by authors
	LI Yongmei
	TAN Zihao
	WANG Xinguang
	TAO Xipeng
	YANG Yanhong
	LIU Jide
	LIU Jinlai
	LI Jinguo
	ZHOU Yizhou
	SUN Xiaofeng

URL:

https://www.ams.org.cn/EN/10.11900/0412.1961.2023.00275 OR https://www.ams.org.cn/EN/Y2025/V61/I7/1049

Fig.1 Schematic of the standard heat treatment regime (AC—air cooling)

Fig.2 Curves of mass gain vs oxidation time (t) in the early 10 h (a) and in 200 h (b)

Fig.3 XRD spectra of oxidation products formed after 1, 5, 40, 100, and 200 h at 1120 ^oC

Fig.4 Surface macromorphologies (a) and SEM images of oxidation products (b-g) of samples after oxidizing at 1120 ^oC for 1 h (b), 5 h (c), 40 h (d), 100 h (e, f), and 200 h (g)

Table 1 Chemical compositions of surface oxidation products analyzed by EPMA

Fig.5 SEM images of longitudinal section of samples after oxidizing at 1120 ^oC for 1 h (a), 5 h (b), 40 h (c), 100 h (d), and 200 h (e) (ORD—oxdation reaction domain)

Table 2 Chemical compositions of oxidation products in Figs.5c and d in longitudinal section analyzed by EPMA

Fig.6 SEM images of microstructure evolution 20-40 µm near the Al-depletion region (a1-e1) and 2 mm away from the surface (a2-e2) of samples after oxidizing at 1120 ^oC for 1 h (a1, a2), 5 h (b1, b2), 40 h (c1, c2), 100 h (d1, d2), and 200 h (e1, e2)

Fig.7 Kinetic curves of experimental alloys after oxidizing at 1120 ^oC for 200 h (Δm—oxidation mass gain per unit area, n—oxidation reaction index, $k p 1$ and $k p 2$ indicate the parabolic oxidation rate constants for the first 40 h and after 40 h, respectively)
(a) logarithmic of Δmvs time (b) Δm²vs time

Alloy	Temperature ^oC	Time h	$k p$ g²·cm^-4·s^-1	Alloy	Temperature ^oC	Time h	$k p$ g²·cm^-4·s^-1
Experimental	1120	0-40	4.67 × 10^-10	2^[8]	1100	0-5	9.44 × 10^-13
Experimental		60-200	3.28 × 10^-9			20-200	1.95 × 10^-12
1^[20]	1100	0-25	5.50 × 10^-12	3^[9]	1100	0-100	7.22 × 10^-13
		50-100	8.06 × 10^-12	4^[21]	1100	0-16	2.76 × 10^-10
		130-200	2.77 × 10^-12			20-100	3.14 × 10^-11

Table 3 Comparisons of parabolic kinetic oxidation constant between the experimental alloy and other alloys^[8,9,20,21]

Table 4 Chemical compositions of the four alloys^[8,9,20,21]

Fig.8 Schematic of oxidation mechanism of alloy at 1120 ^oC

Fig.9 Mass gain curve of the experimental alloy after continuous oxidizing at 1150 ^oC (a) and photo of peeling oxide of alloy after discontinous oxidizing at 1120 ^oC for 100 h (b)

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