Papers by Author: Karel Obrtlík

Abstract: Polycrystalline cast nickel-based superalloy IN738LC is employed for critical parts of gas turbine components in the power industry, aircraft engines, and the marine sector. These components undergo severe degradation by low cycle fatigue caused by thermal gradients, particularly during start-up and shut-down periods. The present work reports the cyclic deformation behaviour and fatigue damage of IN738LC during high-temperature isothermal fatigue. Cylindrical specimens were cyclically deformed under strain control with constant total strain amplitude in symmetrical cycling at 800 °C and 950 °C in air. The microstructure is typical of coarse dendritic grains with carbides, eutectic, and shrinkage pores. SEM imaging revealed a γ matrix with coherent L1₂ γ′ precipitates with bimodal morphology. Cyclic hardening/softening curves, cyclic stress-strain response, and fatigue life diagrams were determined. An increase in testing temperature is associated with a significant decrease in stress amplitude and an increase in plastic strain amplitude. The fatigue life gradually decreases with increasing temperature. The fracture surfaces and polished sections parallel to the specimen axis were examined to study damage mechanisms in cyclic loading at high temperatures.

Abstract: The contribution focuses on the description of failure mechanism of atmospheric plasma sprayed multilayer thermal barrier coatings subjected to calcia-magnesia-alumino-silicate (CMAS) environmental attack. To identify exothermic and endothermic reactions which occurred during heating/cooling by means of calorimetry was also utilized initial yttria stabilized zirconia (YSZ) powder subsequently used for thermal spraying of multilayer thermal barrier coating system (TBCs), CMAS powder later on utilized for thin layer deposition and its mixture. Atmospheric plasma spray technique was used to produce the TBCs on a grit blasted nickel-based superalloy substrates, where CoNiCrAlY powder was used for deposition of a bond coat and YSZ powder was sprayed as a top coat. In accordance to the aerospace standard the thin layer of CMAS was deposited on as sprayed TBCs samples surface from its colloidal solution by paint brush method. Burner-rig test, utilizing direct propane-oxygen flame, was used for thermal cyclic exposition of the multilayer coated samples at the temperature of 1150 °C. Samples after thermal cyclic exposure test were investigated by means of materialographic analysis approaches. The significant reduction in life-time of CMAS coated YSZ top coat was observed due to lower melting point phase formation and molten silicate crystallization within the pores providing the spallation identified as a major mechanism of TBCs failure.

Abstract: The present work is focused on the study of crack initiation during low cycle fatigue (LCF) loading of the second generation nickel-based superalloy MAR-M247 treated with hot isostatic pressing. LCF tests were conducted on cylindrical specimens in symmetrical push-pull cycle under strain control with constant total strain amplitude and strain rate at 800 °C in air atmosphere. Selected specimens were electrolytically polished to facilitate surface relief observations. Crack initiation sites were studied by means of scanning electron microscopy (SEM) in dual beam microscope TESCAN LYRA 3 XMU FESEM equipped with focus ion beam (FIB). The microstructure of the material is characterised by coarse dendritic grains with numerous carbides and small casting defects. The average grain size was 2.1 ± 0.3 mm. Fractographic analysis revealed the fatigue crack initiation sites and their relation to the casting defects and material microstructure. Casting defects, carbide inclusions and interdendritic areas were found to be important crack nucleation sites. Specimens’ surface observations revealed the formation of pronounced surface relief with short worm-like markings. Fatigue crack initiation in these places is documented and discussed.

Abstract: Thermal barrier coatings are widely used to protect the substrate from high temperature and extremely aggressive environments in gas engines. In the present article, authors have been studied degradation of complex thermal barrier coating system deposited on polycrystalline nickel superalloy IN 713LC. The substrate material was grit blasted with alumina (Al₂O₃) particles prior to air plasma deposition of CoNiCrAlY bond coat. Top coat consists of conventional zirconia (ZrO₂) stabilized by yttria (Y₂O₃) -YSZ ceramic in combination with a eutectic nanocrystalline ceramic Eucor made of zirconia (ZrO₂), alumina (Al₂O₃) and silicia (SiO₂) –in the ratio of 50/50 in wt. %. The top coat was deposited using water stabilized plasma. Test specimens with the TBC coating system were fatigued under strain control condition in fully reversed symmetrical push-pull cycles at 900°C in air. The microstructure of TBC was characterized with scanning electron microscopy and energy dispersion X-ray analysis. The coating hardness and thickness were measured. Fracture surface and polished sections parallel to the specimen axis were examined to study damage mechanisms in coatings under cyclic loading at high temperature. TBC delamination was observed at the top coat/bond coat interface after cyclic loading at high temperature. Fatigue crack initiation sites are documented. Majority of fatigue cracks start from the surface and top coat/bond coat interface.

Abstract: Two γ-based TiAl alloys with 7 at.% of Nb, alloyed with 2 at.% Mo and 0.5 at.% C, were studied. A heat treatment leading to very fine lamellar microstructure was applied on both alloys. Microstructure after the heat treatment was described and mechanical properties including fatigue behaviour were measured. The as-received material alloyed with C possesses high strength and very limited ductility, especially at RT. After application of selected heat treatment it becomes even more brittle; therefore, this process could be considered as not appropriate for this alloy. On the contrary, in the case of Mo alloyed material, both strength and ductility are improved by the heat treatment at RT and usual working temperature (~750 °C). Presence of the β phase is responsible for this effect. The selected heat treatment thus can be an alternative for this alloy to other thermomechanical treatments as high temperature forging.

Abstract: Barium-Magnesium-Aluminium-Silicate (BMAS) powder was produced from a mixture of initial compounds BaO–MgO–Al₂O₃–SiO₂ by means of solid state synthesis at the temperature of 1200 °C for 3 hours in a laboratory furnace. Synthetized powder was crushed into the fraction of 15-45 μm in a planetary ball mill. Thermal barrier coating system consisting of CoNiCrAlY (bond coat) and BMAS (top coat) was sprayed by atmospheric plasma spray technique onto the polycrystalline nickel-based superalloy substrate. During plasma spraying process, the BMAS underwent phase transformation and the amorphous phase within the top coat was produced. Therefore, after the spraying, several samples were crystallized via annealing in a furnace (4 hours at 1200 °C or 24 hours at 1000 °C) or by subjecting them to several passes of plasma jet. Both samples with an amorphous phase and fully-crystallized samples were subjected to the fire in a burner-rig test (propane-oxygen flame, single 3 + 3 minute cycle), where the top coat reached the temperature of 1150 °C. Top coat failure occurred during the cooling period due to the transformation of the amorphous phase into the crystalline one and/or due to the difference in thermal conductivity and expansion between the top coat and the bond coat.

Abstract: The present work is focused on the study of microstructure and low cycle fatigue behavior of the first generation nickel-base superalloy IN 713LC (low carbon) and its promising second generation successor MAR-M247 HIP (hot isostatic pressing) at 900 °C. Microstructure of both alloys was studied by means of scanning electron microscopy (SEM). The microstructure of both materials is characterized by dendritic grains, carbides and casting defects. Size and morphology of precipitates and casting defects were evaluated. Fractographic observations have been made with the aim to reveal the fatigue crack initiation place and relation to the casting defects and material microstructure. Low cycle fatigue tests were conducted on cylindrical specimens in symmetrical push-pull cycle under strain control with constant total strain amplitude and strain rate at 900 °C in air. Hardening/softening curves, cyclic stress-strain curve and fatigue life data of both materials were obtained. Cyclic stress-strain curve of MAR M247 is shifted approximately to 120 MPa higher stress amplitudes in comparison with IN 713LC. Significantly higher fatigue life of MAR-M247 has been observed in Basquin representation. On the other hand IN 713LC shows prolonged lifetime compared with MAR-M247 in the Coffin-Manson representation. Results obtained from high temperature low cycle fatigue tests are discussed.

Abstract: The present work is focused on the study of low cycle fatigue behavior of grit blasted nickel-base superalloy Inconel 713LC (IN 713LC). Grit blasting parameters are obtained. Button end specimens of IN 713LC in as-received condition and with grit blasted surface were fatigued under strain control with constant total strain amplitude in symmetrical cycle at 900 °C in air. Hardening/softening curves, cyclic stress-strain curve and fatigue life data of both materials were obtained. Both materials exhibit the same stress-strain response. It has not been observed any improvement or reduction of low cycle fatigue life in representation of total strain amplitude versus number of cycles to failure of grit blasted material in comparison with as-received material. Surface relief and fracture surface were observed in SEM. The little effect of surface treatment on fatigue characteristics is discussed.

Abstract: The 8 wt. % yttria stabilized zirconia top coat (TC) and the CoNiCrAlY bond coat (BC) were sprayed onto the surface of newly developed fine-grained cast polycrystalline nickel-based superalloy Inconel 713LC by means of atmospheric plasma spraying (APS). As-prepared samples were isothermally exposed at the temperature of 1050 °C for 200 hours in an ambient atmosphere. Structural changes in the thermal barrier coatings (TBC) system after thermal exposure were studied by means of scanning electron microscope equipped with an energy dispersive microanalyzer. Critical weak points were identified on both the substrate-bond coat and bond coat-top coat interfaces.

Abstract: Commercially pure aluminium powder and a mixture of aluminium and silicon powders, both in a liquid amyl acetate-based organic binder, were sprayed onto the surface of Inconel 713LC nickel base superalloy. A two-stage heat treatment process in an argon atmosphere flow was designed and applied to produce nickel aluminide diffusion coatings. Two coating systems composed of different layers with gradual changes in chemical composition and phase quantities were formed. Scanning electron microscope, scanning electron microscope/focused ion beam, both equipped with energy dispersive microanalyzers, were utilized to characterize the microstructure and chemical composition of the coatings.