Corrosion behavior of plasma-sprayed coatings on a Ni-base superalloy in Na<Subscript>2</Subscript>SO<Subscript>4</Subscript>-60 Pct V<Subscript>2</Subscript>O<Subscript>5</Subscript> environment at 900 °C

The shrouded plasma spray process was used to deposit NiCrAlY, Ni-20Cr, Ni₃Al, and Stellite-6 metallic coatings on a Ni-based superalloy (62Ni-23Cr-1.48Al-0.80Mn-0.37Si-0.10Cu-0.025C-bal Fe). NiCrAlY was used as a bond coat in all cases. Hot corrosion studies were conducted on uncoated as well as plasma-spray-coated superalloy specimens after exposure to molten salt at 900 °C under cyclic conditions. The thermogravimetric technique was used to establish the kinetics of corrosion. X-ray diffraction (XRD), scanning electron microscopy/energy-dispersive X-ray analysis (SEM/EDAX) and electron-probe microanalysis techniques were used to analyze the corrosion products. The uncoated superalloy suffered accelerated corrosion in the form of intense spalling of the scale. The NiCrAlY coated specimen showed a minimum weight gain, whereas the Stellite-6 indicated a maximum weight gain among the coatings studied. All the coatings were found to be successful in developing resistance against hot corrosion, which may be attributed to the formation of oxides, and spinels of nickel, aluminum, chromium, or cobalt.     

Steam oxidation of 80Ni-20Cr high-velocity oxyfuel coatings on 9Cr-1Mo steel: Diffusion-induced phase transformations in the substrate adjacent to the coating

The steam oxidation resistance of 80Ni-20Cr coatings on modified 9Cr-1Mo steel has been evaluated in the temperature range of 600 °C to 750 °C. High-velocity oxyfuel (HVOF) spray was used for the coating process. The steam-oxidized specimens exhibited the diffusion of iron from the substrate to the coating and diffusion of nickel from the coating to the substrate. Nickel diffusion to the substrate adjacent to the coating induced the microstructural changes. Micro X-ray diffraction (XRD) studies and energy-dispersive spectroscopy (EDS) point analysis on these transformed zones revealed that the newly formed phases are the austenite in the high-Ni-concentration region and the martensite in the low-Ni-concentration region. Microhardness studies showed higher hardness values in the martensite zones.     

High Cycle Fatigue of (Fe,Ni, Co)3V type alloys

High cycle fatigue tests in vacuum have been performed on ordered (Fe, Co, Ni)₃V alloys between 25 °C and 850 °C. Heat-to-heat variations in fatigue properties of a Co-16.5 wtpct Fe-25 pct alloy, LRO-1, appeared to be due to differing quantities of grain boundary precipitates. Modification of this alloy with 0.4 pct Ti, to produce an alloy designated LRO-23, reduced the density of grain boundary precipitates and increased ductility, resulting in superior fatigue strength at high temperatures. The fatigue lives of LRO-1 and LRO-23 decreased rapidly above 650 °C, and increased intergranular failure was noted. The fatigue resistance of a cobalt-free alloy, Fe-29 pct Ni-22 pct V-0.4 pct Ti (LRO-37), was examined at 25 °C, 400 °C, and 600 °C; there was little evidence for intergranular fracture at any of these temperatures. Fatigue behavior of the LRO alloys is compared to that of conventional high temperature alloys.     

Effect of preoxidation and grain size on ductility of a boron-doped Ni3Al at elevated temperatures

The ductility of a preoxidized Ni₃Al (Ni-23Al-0.5Hf-0.2B. at.%) alloy with various grain sizes (17–193 μm) was evaluated by means of tensile tests at 600 and 760°C in vacuum. The preoxidation does not affect the ductility of the finest-grained material at either temperature, whereas it causes severe embrittiement in the largest-grained material, especially at 760°C. Auger studies revealed very little oxygen penetration along grain boundaries in the finest-grained material but substantial oxygen penetration in the largest-grained one. A continuous, thin Al-rich oxide layer which forms on the fine-grained samples protects the underlying alloy from oxygen penetration, preventing any loss of ductility, whereas the nickel-rich oxide which forms on the large-grained samples allows oxygen to penetrate along grain boundaries, causing severe embrittiement. The grain boundaries act as short-circuit paths for rapid diffusion of aluminum atoms from the bulk to the surfaces, and this is responsible for the change in oxidation product from Ni-rich to Al-rich oxide with decreasing grain size.     

Improvement of Ti alloy fatigue properties by Pt ion plating

The effect of Pt ion plating on the high cycle axial fatigue life of Ti-6Al-2Sn-4Zr-2Mo specimens was studied at room temperature and 455 °C. Unlike other coatings, the plated material tested in this work showed an increase in fatigue strength when compared to uncoated material. The fatigue strength improvement was greater at 455 °C than at room temperature. Coated specimens cycled close to the fatigue limit at 455 °C demonstrated the highest improvement, which was associated with subsurface fatigue crack initiation. The uncoated specimens, tested under similar conditions, failed by cracking at the surface. Sectioning analysis showed no defects in the subsurface initiation sites. The initiation was related to groups of similarly aligned coarse α platelets. It is suggested that the Pt ion plating caused some surface hardening as well as oxidation resistance at elevated temperatures leading to the suppression of surface crack initiation.     

Fatigue of Ni-Ai-Mo aligned eutectics at elevated temperatures

The elevated-temperature mechanical behavior of two aligned eutectics (Ni-8.1 wt pct Al-26.4 wt pct Mo and Ni-6.3 wt pct Al-31.2 wt pct Mo) has been investigated utilizing monotonic and cyclic testing in vacuum. Tensile yield strength and fatigue resistance increased from 25 to 725 °C, but then were reduced at 825 °C. The fatigue lives of specimens tested at 725 °C decreased sharply with decreasing frequency. A shift from surface to internal crack initiation was observed upon increasing the test temperature from 725 to 825 °C. Stage II crack propagation was observed at both temperatures, in contrast to stage I cracking at 25 °C. The test results are compared to those for other nickel and cobalt-base aligned eutectics to show that the frequency effect on fatigue life is not limited to the Ni-AI-Mo system. formerly Graduate Assistant in the Department of Materials Engineering, Rensselaer Polytechnic Institute     

Effects of temperature and environment on the tensile and fatigue crack growth behavior of a Ni3AI-base alloy

The effects of temperature, frequency, and environment on the tensile and cyclic deformation behavior of a nickel aluminide alloy, Ni-9.0 wt pct Al-7.97 pct Cr-1.77 pct Zr (IC-221), have been determined. The tensile properties were obtained in vacuum at elevated temperatures and in air at room temperature. The alloy was not notch sensitive at room temperature or at 600 °C, unlike Cr-free Ni₃Al + B alloys. In general, crack growth rates of IC-221 increased with increasing temperature, decreasing frequency, exposure to air, or testing at higherR ratios. At 25 °C, crack growth rates were slightly higher than for a previously investigated Cr-free Ni₃Al alloy. However, at 600 °C, the crack growth rates for IC-221 were lower than for the Cr-free alloy. Substantial frequency effects were noted on crack growth of IC-221 at both 600 °C and 800 °C in both air and vacuum, especially at highK. The relative contributions of creep and environmental interactions to fatigue crack growth are discussed.     

Diffusional creep and creep-degradation in dispersion-strengthened Ni-Cr base alloys

Dispersoid-free regions were observed in the dispersion-strengthened alloy TD-NiCr (Ni-20 Cr-2 ThO₂) after, slow strain rate testing (stress rupture, creep, and fatigue) in air from 1145 to 1590 K. Formation of the dispersoid-free regions appears to be the result of diffusional creep. The net effect of creep in TD-NiCr is the degradation of the alloy to a duplex microstructure. Creep degradation of TD-NiCr is further enhanced by the formation of voids and intergranular oxidation in the dispersoid-free bands. Void formation was observed after as litte as 0.13 pct creep deformation at 1255 K. The dispersoid-free regions apparently provide sites for void formation and oxide growth since the strength and oxidation resistance of Ni-20 Cr is much less than Ni-20 Cr-2 ThO₂. This localized oxidation does not appear to reduce the static load bearing capacity of TD-NiCr since long stress-rupture lives were observed even with heavily oxidized microstructures, but this oxidation does significantly reduce the ductility and impact resistance of the material. Dispersoid-free bands and voids also were observed in two other dispersion-strengthened alloys, TD-NiCrAl (Ni-16Cr-4 Al-2 ThO₂) and IN-853 (Ni-20 Cr-2.5 Ti-1.5 Al-1.3 Y₂O₃). Thus, it appears that diffusional creep is characteristic of dispersion-strengthened alloys and can play a major role in the creep degradation of these materials.     

Test temperature and strain rate effects on the properties of a tungsten heavy alloy

Liquid phase sintered tungsten heavy alloy specimens with a 90W-7Ni-3Fe composition were tested for temperature and strain rate effects on mechanical behavior. Both fracture stress and strain were measured for samples tested at 20, 300, or 600 °C, with crosshead speeds ranging from 0.004 to 400 mmJs in an argon atmosphere. Fracture surface examinations showed a dramatic increase in tungsten cleavage as the ductility increased. The effect of an increasing strain rate is a slight strength increase with a concomitant ductility decrease. Alternatively, higher test temperatures degrade strength with a nonsystematic effect on ductility; maximum ductility occurs at 300 °C and a slow strain rate. Surface oxidation at 600 °C greatly degrades ductility. The results are mathematically modeled using classic strain rate dependent equations.     

Mechanical behavior and microcracking of cubic ternary zirconium trialuminides

Vickers microhardness, compressive properties from room temperature (RT) to 900 °C, and microcracking development of cubic ternary zirconium trialuminides macroalloyed with Cu (Al-12.5Cu-25Zr), Mn (Al-9Mn-25Zr), and Cr (Al-8Cr-25Zr) (atomic percent) were investigated. It is shown that microhardness exhibits a strong dependence on load. It does not depend in any systematic way on the atomic number of macroalloying element (Cu, Mn, or Cr) but seems to be affected by the zirconium content. It is also found that the yield stress exhibits a strong positive dependence on temperature particularly in Al-9Mn-25Zr and Al-12.5Cu-25Zr. Microcracking experiments have shown that microcracks nucleate in many instances on pre-existing micropores. To a large extent, the proliferation of cracks also occurs by connecting the pores. It is observed that the work-hardening rate at room temperature is very high for cubic Al₃Zr-base intermetallic alloys, being in the range 20 to 30 GPa. It decreases with increasing temperature up to 400 °C to 500 °C and then slightly increases up to 900 °C.     

Fatigue Crack Growth Behaviour of Conventional and Modified IN 718 Superalloys at 650 °C

In the present investigation, the fatigue crack growth behaviour of modified IN 718 superalloy (Ni-0.02 %, C-19.04 %, Cr-19.31 %, Fe-3.04 %, Mo-4.73 %, Nb-1.01 %, Al-1.16 %, Ti-0.0033 %, B, all in wt%) has been compared with conventional IN 718 superalloy (Ni-0.02 %, C-19.0 %, Cr-19.35 %, Fe-3.0 %, Mo-5.10 %, Nb-0.50 %, Al-1.00 %, Ti-0.0033 %, B, all in wt%) at 650 °C. Modified IN 718 superalloy exhibits marginally lower crack growth rate as compared to conventional alloy and was attributed to roughness induced crack closure.     

Effect of thermal spray on the microstructure and adhesive strength of high-velocity oxy-fuel-sprayed Ni-Cr coatings on 9Cr-1Mo steel

Coatings of 80Ni-20Cr and 50Ni-50Cr on a 9Cr-1Mo steel substrate were produced by high-velocity oxy-fuel (HVOF) spraying to protect the steel against steam oxidation in ultrasupercritical (USC) boilers. The oxidation studies on the coated specimens showed good protection against the scale growth on the steel substrate. Both the 80Ni-20Cr and 50Ni-50Cr coatings formed a thin protective oxide film on the coating surface. The 80Ni-20Cr coating showed Fe diffusion from the substrate to the coating and nickel diffusion from the coating to the substrate during the oxidation process. In the case of 50Ni-50Cr coatings, the diffusion process was reduced, but a continuous layer of chromium carbide was observed at the coating/substrate interface during the oxidation. The adhesive/cohesive strength of these coatings was evaluated on aged specimens at 750 °C by using a simple tensile test. The results of the as-coated 80Ni-20Cr specimens showed an adhesive-strength value of 68 MPa. On extended aging, the strength of the coating increased beyond the detection limit of the resin. The nickel diffusion from the coating to the substrate and the iron diffusion from the substrate to the coating caused the increased adhesive strength. In the case of 50Ni-50Cr, the as-coated specimens showed an average adhesive strength of 76 MPa and showed a decreasing trend on the aged specimens. The formation of chromium carbide at the interface caused inferior values in the adhesive/cohesive strength of the 50Ni-50Cr coatings. The chromium carbide formed on the coating/substrate interface was identified as M₂₃C₆-type carbide.     

The effect of protective coatings on the high temperature properties of a gamma prime-strengthened Ni-base superalloy

The present study examined the influence of chrome-aluminide coatings on the creep and stress rupture properties of a wrought Udimet-520 nickel-base superalloy used in gas turbine blade applications. Creep and stress rupture tests were conducted at 802 °C (1475 °F) on coated and uncoated wrought bars in the fully heat treated condition. The tests showed that the application of the chrome-aluminide coatings caused a marked deterioration in rupture strength and ductility. Masking procedures used to protect the turbine blade roots during coating of the Ni-base superalloy also affected the rupture strength or rupture ductility. The mechanical behavior in the coated creep resistant alloy was correlated with the microstructure and is discussed in terms of possible controlling processes.     

Mechanical properties of isothermally aged high-nitrogen stainless steel

The effects of nitride (Cr₂N) precipitation on the tensile, impact, and hardness properties of a typical high-nitrogen, low-carbon austenitic stainless steel (SS), nominally Fe-19Cr-5Mn-5Ni-3Mo-0.024C0.69N, were determined. Annealed and cold-rolled (20 pct reduction in thickness) specimens were isothermally aged at 700 °C and 900 °C for times ranging from 0.1 to 10 hours. Only grain boundary Cr₂N precipitation occurred in annealed materials aged at 700 °C. Precipitation at 900 °C occurred sequentially at grain boundaries, by cellular precipitation, and, finally, by transgranular precipitation within the matrix. Nitride precipitation had little effect on yield and ultimate strengths but reduced tensile ductility and impact toughness. Embrittlement occurred due to grain boundary separation (700 °C and 900 °C) and fracture through cellular precipitate regions, initiated at nitrides (900 °C). Prior deformation increased precipitation kinetics and had a controlling influence on nitride morphology, enhancing grain boundary and transgranular Cr₂N and retarding cellular precipitation. Nitride structures produced in cold-rolled materials were just as detrimental to material plasticity as those produced in annealed materials, but prior deformation increased the kinetics of embrittlement. Due to strain recovery, the yield and ultimate strengths of cold-rolled materials decreased with aging timeand temperature.     

Mechanical properties of isothermally aged high-nitrogen stainless steel

The effects of nitride (Cr₂N) precipitation on the tensile, impact, and hardness properties of a typical high-nitrogen, low-carbon austenitic stainless steel (SS), nominally Fe-19Cr-5Mn-5Ni-3Mo-0.024C0.69N, were determined. Annealed and cold-rolled (20 pct reduction in thickness) specimens were isothermally aged at 700 °C and 900 °C for times ranging from 0.1 to 10 hours. Only grain boundary Cr₂N precipitation occurred in annealed materials aged at 700 °C. Precipitation at 900 °C occurred sequentially at grain boundaries, by cellular precipitation, and, finally, by transgranular precipitation within the matrix. Nitride precipitation had little effect on yield and ultimate strengths but reduced tensile ductility and impact toughness. Embrittlement occurred due to grain boundary separation (700 °C and 900 °C) and fracture through cellular precipitate regions, initiated at nitrides (900 °C). Prior deformation increased precipitation kinetics and had a controlling influence on nitride morphology, enhancing grain boundary and transgranular Cr₂N and retarding cellular precipitation. Nitride structures produced in cold-rolled materials were just as detrimental to material plasticity as those produced in annealed materials, but prior deformation increased the kinetics of embrittlement. Due to strain recovery, the yield and ultimate strengths of cold-rolled materials decreased with aging time and temperature.     

Evaluation of fatigue properties for aged 9Cr-1Mo steel

Low cycle fatigue tests of 9Cr-1Mo steel aged at 600°C for 5000 h and 10000 h were conducted at RT-600°C. Fatigue life was not decreased with aging. Cyclic softening was seen with cycles in both unaged and aged specimens. Aging decreased the amount of softening at RT and 400°C but increased it at 600°C. The precipitate species were not changed with aging upto 5000 h but Laves phase was precipitated after 10000 h aging. Fatigue life of 9Cr-1Mo steel aged to 10000 h is dependent on dislocation slip behavior rather than the amount and coarsening of precipitate.     

Isothermal fatigue of an aluminide-coated single-crystal superalloy: Part I

The isothermal fatigue behavior of a high-activity aluminide-coated single-crystal superalloy was studied in air at test temperatures of 600 °, 800 °, and 1000 °. Tests were performed using cylindrical specimens under strain control at ≈0.25 Hz; total strain ranges from 0.5 to 1.6 pct were investigated. At 600 °, crack initiation occurred at brittle coating cracks, which led to a significant reduction in fatigue life compared to the uncoated alloy. Fatigue cracks grew from the brittle coating cracks initially in a stage II manner with a subsequent transition to crystallographic stage I fatigue. At 800 ° and 1000 °, the coating failed quickly by a fatigue process due to the drastic reduction in strength above 750 °, the ductile-brittle transition temperature. These cracks were arrested or slowed by oxidation at the coating-substrate interface and only led to a detriment in life relative to the uncoated material for total strain ranges of 1.2 pct and above 800 °. The presence of the coating was beneficial at 800 ° for total strain ranges less than 1.2 pct. No effect of the coating was observed at 1000 °. Crack growth in the substrate at 800 ° was similar to 600 °; at 1000 °, greater plasticity and oxidation were observed and cracks grew exclusively in a stage II manner. Formerly Research Student, Department of Materials Science and Metallurgy, University of Cambridge. Formerly Lecturer, Department of Materials Science and Metallurgy, University of Cambridge CB2 3QZ, United Kingdom.     

Thermal fatigue of a heat-resistant Fe-0.45C-26Cr-33Ni-2Si-2Nb alloy

The thermal fatigue of a heat-resistant Fe-0.45C-26Cr-33Ni-2Si-2Nb alloy is studied during thermal cycling in the temperature range 50–900°C up to 1000 cycles. The alloy is investigated in the initial as-cast state and after isothermal annealing during 1000 h at a temperature of 800, 900, 1000, or 1100°C; these conditions imitate the temperature conditions of operation and the structural state of various layers in a reaction pipe in the radiant furnace coils of ethylene production installations. After isothermal annealing, the thermal fatigue life of the alloy is found to decrease by a factor of 1.7–1.2 as compared to the initial as-cast state. It is shown that isothermal annealing and subsequent thermal cycling lead to the formation of carbide precipitates of various sizes in the alloy structure that affect the thermal fatigue life of the alloy. Thermal fatigue cracks are shown to form and grow predominantly at the sites of accumulation of fine carbide precipitates. Coarse (>10 μm) precipitates retard crack growth, and cracks branch near such precipitates.     

Effects of temperature on the fatigue crack growth behavior of cast gamma-based titanium aluminides

This article reports the results of an experimental study of the effects of temperature (25 °C, 450 °C, and 700 °C) on the fatigue crack growth behavior of three near-commercial cast gamma titanium aluminide alloys (Ti-48Al-2Cr-2Nb, Ti-47Al-2Mn-2Nb+0.8 pct TiB₂, and Ti-45Al-2Mn-2Nb+0.8 pct TiB₂). The trends in the fatigue crack growth rate data are explained by considering the combined effects of crack-tip deformation mechanisms and oxide-induced crack closure. Faster fatigue crack growth rates at 450 °C are attributed to the high incidence of irreversible deformation-induced twinning, while slower crack growth rates at 700 °C are due to increased deformation by slip and the effects of oxide-induced crack closure.     

Mechanical Property Enhancement of Ti-6Al-4V by Multilayer Thin Solid Film Ti/TiO2 Nanotubular Array Coating for Biomedical Application

With the intention of improving the mechanical properties of Ti-6Al-4V, samples were first coated with pure titanium using the physical vapor deposition (PVD) magnetron sputtering technique. The Taguchi optimization method was used to attain a higher coating on substrate adhesion. Second, pure titanium-coated samples with higher adhesion were anodized to generate TiO₂ nanotubes. Next, the TiO₂-coated specimens were heat treated at annealing temperatures of 753.15 K and 923.15 K (480 °C and 650 °C). The XRD results indicate that the varying heat treatment temperatures produced different phases, namely, anatase [753.15 K (480 °C)] and rutile [923.15 K (650 °C)]. Finally, the coated samples’ mechanical properties (surface hardness, adhesion, and fretting fatigue life) were investigated. The fretting fatigue lives of TiO₂-coated specimens at 753.15 K and 923.15 K (480 °C and 650 °C) annealing temperatures were significantly enhanced compared to uncoated samples at low and high cyclic fatigue. The results also indicate that TiO₂-coated samples heat treated at an annealing temperature of 753.15 K (480 °C) (anatase phase) are more suitable for increasing fretting fatigue life at high cyclic fatigue (HCF), while at low cyclic fatigue, the annealing temperature of 923.15 K (650 °C) seemed to be more appropriate. The fretting fatigue life enhancement of thin-film TiO₂ nanotubular array-coated Ti-6Al-4V is due to the ceramic nature of TiO₂ which produces a hard surface as well as a lower coefficient of friction of the TiO₂ nanotube surface that decreases the fretting between contacting components, namely, the sample and friction pad surfaces.