Advanced Materials Research Vol. 278

Abstract: Although Ni-base superalloys meet the gas turbine needs of today, they are used very close to their melting range. Demands for applications at higher temperatures are presently met partly through component cooling and application of thermal barrier coatings. However, this approach can not be sustained indefinitely unless the base metal melting temperature is also significantly increased. Rhenium addition can substantially increase the melting point in Co-base alloys and thereby provide a unique opportunity in the development of new alloys for very high temperatures – e.g. for applications at +100°C metal temperature above present day single crystal Ni-base superalloys. The design considerations behind the Co-Re alloy development are presented in this paper. Selected results from the alloy development studies are also presented.

Abstract: Ni-based alloys are the most widely used alloy system in high-temperature applications. However, the use of Ni-based alloys is limited to temperatures below 1100°C. The experimental Co-Re-Cr-based alloys are promising for high-temperature applications for service temperatures beyond 1200°C. A complete miscibility in the Co-Re system allows to steadily elevate the melting point of the system with the rhenium content. In addition, rhenium takes the role as solid solution strengthening element. In the case of Co-based alloys, the oxidation resistance at high temperature is mainly based on the formation of a protective Cr2O3 scale. The purpose of the present investigations is to gain an insight into the oxidation mechanisms of the model Co-Re-Cr alloys and to find ways to improve oxidation resistance of this class of materials. Earlier investigations of the authors showed a rather poor oxidation resistance during exposure to laboratory air. Oxidation at 1000°C in air yielded an oxide scale that consists of a Co-oxide outer layer on a thick and porous Co-Cr oxide and a semicontinuous and therefore non-protective Cr-oxide film on the base metal substrate. As a consequence of the lacking protectiveness of the oxide layer the vaporization of rhenium oxide takes place and hence leads to a rapid loss of Re. The aim of recent investigations is to study the effect of Si on the high-temperature oxidation behaviour of Co-Re-Cr alloys by means of kinetic and microstructural examinations. It was found that Si stabilizes the Cr2O3 scale, enhancing the oxidation resistance significantly. Hence, the synergetic effect of chromium with silicon could be considered as an encouraging perspective to improve the oxidation resistance of Co-Re-Cr alloys. Apart from that, other concepts to enhance the oxidation resistance of this class of materials are discussed, such as the formation of a borosilicate layer or protective Al2O3 scale on the substrate surface.

Abstract: Development and processing of high-temperature materials is the key to technological progress in engineering areas where materials have to meet extreme requirements. Examples for such areas are the aerospace and automotive industries. New structural materials have to be stronger, stiffer and lighter to withstand the extremely demanding conditions in the next generation of aero- and automotive engines. Intermetallic -TiAl based alloys exhibit numerous attractive properties which meet these demands. These properties include high melting point, low density, high specific elastic modulus, good oxidation and burn resistance, and high specific strength up to application temperatures of 700 to 800°C. Thus, current -TiAl based alloys outperform advanced Ti-based alloys and have the potential to replace heavy Ni-based superalloys.

Abstract: In order to make the TiAl Intermetallics-based materials more competitive with conventional superalloys, further work on microstructure modification and alloying process has been carried out specific to the cast and wrought process, respectively. It is proved that directional lamellar microstructures can be formed in the cast TiAl. Those microstructures have demonstrated preponderant mechanical properties under unidirectional load after the cast porosity being removed by HIP at proper temperatures. This microstructure design specific to the rotating parts has benefited the endurance capacity of cast TiAl turbochargers. On the other hand, the additions of Gd have shown significant effect in refining the lamellar microstructures of forged TiAl alloys but do not bring out the detrimental influence to the tensile ductility. The reason is that the Gd-containing precipitates can greatly impede the growth of  grains while themselves dispersing during the thermal process. Upon those technology advances, the further success of TiAl alloys’ applications is prospected.

Abstract: Actual alloy and process development for high temperature turbine applications in the aerospace sector is strongly aimed at reaching the high demands on reduction of CO2 emissions responsible for the green house effect. Based on weight reduction the main objective resides in improving engine performance and efficiency. Last generation intermetallic titanium aluminides (γ TiAl) have a big potential to reach this goals. γ TiAl is nevertheless a very demanding material requiring very sophisticated processing routes. Access has developed a casting route for production of high quality γ TiAl components based on skull induction melting (SIM) and centrifugal investment casting. Although the feasibility of the technology has been already proven in earlier projects, it is still necessary to improve the process for series production of parts with the high quality standards required by the aerospace industry. With aid of a new developed centrifugal casting facility Access and its partners are conducting a comprehensive qualification process for the production of aerospace components, e.g. low pressure turbine blades. Basic issues comprising casting cluster design based on numerical simulation, process control and quality management are being addressed.

Abstract: Chromium-based alloys are considered as potential candidates for applications in hot sections of aero engine turbines due to their high melting point and their moderate density. Some ternary (Cr-Ni-Al) and quaternary (Cr-Ni-Al-Ti) alloys have been designed with the aim to induce precipitation of ordered strengthening precipitates and to promote the formation of a protective alumina scale. These alloys were cast using various techniques in order to assess their microstructural and mechanical properties and their oxidation resistance.

Abstract: This work focuses on the effect of tin additions (2, 5 and 8%) to the MASC alloy (Nb-25Ti-8Hf-2Cr-2Al-18Si) on the microstructure and the oxidation behaviour at 815°C in air. The alloys are mainly constituted of a niobium solid solution plus the () Nb5Si3 silicides. For the higher Sn additions (5 and 8%), a fourth phase is evidenced: it is enriched in Sn and has a crystal structure close to Nb3Sn. The oxidation resistance of these alloys is clearly improved by tin additions: the oxygen inward diffusion is hindered and consequently the fragmentation of the silicides is avoided. Cracks in silicides are no longer observed for the MASC containing 8%Sn. This effect is not attributed to a better efficiency of the oxide scales but rather to the reduction of the niobium solid solution fraction with tin additions.

Abstract: Alloy 59 (NiCr23Mo16Al) with a lot of chromium, molybdenum and nickel possesses excellent resistance not only to reducing but also oxidizing chemicals. Both the Nickel alloy 59 and the superaustenitic steel alloy 31 have already been used as shell materials for tank vehicles or tank containers. Use of these alloys allows the transport of a signifi-cantly more wider variety of chemicals and, especially, waste mixtures than the use of common aus-tenitic steels. Another advantage is the extension of test intervals of for transport tanks. In Germany the “BAM-List – Requirements for Tanks for the Transport of Dangerous Goods” is the basis for substance-related prototype approvals for tank containers designed for the car¬ri¬age of dangerous goods issued by the Federal Institute for Materials Re¬search and Testing (BAM). Com-patibility evaluations of selected metallic material groups as well as polymeric gasket and lining materials under the influence of approximately 7000 dangerous goods and water-polluting sub-stances are published in the BAM-List. Alloy 59 belongs to the group of metallic materials in the BAM-List. Due to the large number of dangerous goods in the BAM-List BAM, IKS Dresden and ThyssenKrupp VDM performed a comprehensive corrosion test programme with welded specimens of the nickel alloy 59 and the superaustenitic steels alloy 926 and alloy 31 in the period 2002 - 2010. Especially In particular alloy 59 and alloy 31 were exposed to a large number of corrosive sub-stances such as various mixtures of both nitric acid/sulphuric acid and nitric acid/phosphoric acid at 55 °C. Other corrosive test substances were different organic and inorganic halogenides, peroxyace-tic acid and molten substances. In the case of molten chemicals such as monochloroacetic acid the test temperature was increased to more than 100 °C. The test results presented in this paper are al-ready included in the 10th edition of the BAM-List and, therefore, available to the customer.

Abstract: Ni-base superalloys are approaching the melting point as their fundamental limitation. For high-temperature components one possibility aiming at a further increase of efficiency, e.g. of jet turbines, is the use of refractory metals. Mo as base material is suitable for operating temperatures far beyond 1200°C. As a consequence of the formation of volatile Mo-oxides, it exhibits no intrinsic oxidation resistance when exceeding 700°C. Mo-Si-B alloys have melting points around 2000°C and retain good mechanical properties and oxidation resistance at very high temperatures. In air, the three-phase Mo-Si-B alloy dealt with in this paper shows excellent oxidation behaviour between 900°C-1300°C as a consequence of the formation of a protective silica scale. Below 900°C, alloys of this class suffer from catastrophic oxidation, leading to an evaporation of Mo-oxide and giving rise to a linear rate law of the weight loss. A protective oxide layer is not formed as a consequence of simultaneous and competitive Mo- and Si-oxide formation. Several approaches are possible to improve the oxidation performance of Mo-Si-B alloys, especially in this moderate temperature range. These include classical alloying, e.g. with Cr aiming for protective Cr-oxide scales, addition of small amounts of reactive elements for microstructure-refinement as well as selective oxidation of silica in oxygen-deficient atmospheres prior to operation in air. The results presented show promising opportunities and indicate that an oxidation protection from room temperature up to 1300°C requires a combination of the suggested approaches.