High-Temperature Oxidation Behavior of Spark Plasma Sintered Ni20Cr-xAl Alloys
Received date: 2022-05-12
Revised date: 2022-12-04
Online published: 2022-12-30
Supported by
National Natural Science Foundation of China(51871051);China Postdoctoral Science Foundation(2022M720678)
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 900oC. 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.
LIU Chengji , SUN Wenyao , CHEN Minghui , WANG Fuhui . High-Temperature Oxidation Behavior of Spark Plasma Sintered Ni20Cr-xAl Alloys[J]. Acta Metall Sin, 2024 , 60(4) : 485 -494 . DOI: 10.11900/0412.1961.2022.00240
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