Solving Recent Challenges for Wrought Ni-Base Superalloys Hardy, M. C.; Detrois, M.; McDevitt, E. T. ...
Metallurgical and materials transactions. A, Physical metallurgy and materials science,
06/2020, Letnik:
51, Številka:
6
Journal Article
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This paper reviews the status of technology in design and manufacture of new wrought polycrystalline Ni-base superalloys for critical engineering applications. There is a strong motivation to develop ...new alloys that are capable of operating at higher temperatures to realize improvements in thermal efficiency, which are necessary to achieve environmental targets for reduced emissions of harmful green-house gases. From the aerospace sector, the development of new powder metallurgy and ingot metallurgy alloys is discussed for disk rotor and static applications. New compositions for powder metallurgy contain about 50 to 55 pct of gamma prime (
γ
′) strengthening precipitates to ensure components operate successfully at temperatures up to 788 °C (1450 °F). In contrast, new compositions for ingot metallurgy aim to occupy a design space in temperature capability between Alloy 718 and current powder alloys that are in-service, and show levels of
γ
′ of about 30 to 44 pct. The focus in developing these alloys was design for manufacturability. To complement the aerospace developments, a review of work to understand the suitability of candidate alloys for multiple applications in Advanced-Ultra Supercritical (AUSC) power plants has been undertaken by Detrois, Jablonski, and Hawk from the National Energy Technology Laboratory. In these power plants, steam temperatures are required to reach 700 °C to 760 °C. The common thread is to develop alloys that demonstrate a combination of high-temperature properties, which are reliant on both the alloy composition and microstructure and can be produced readily at the right price. For the AUSC applications, the emphasis is on high-temperature strength, long-term creep life, phase stability, oxidation resistance, and robust welding for fabrications. Whereas for powder disk rotors in aircraft engines, the priority is enhanced resistance to time-dependent crack growth, phase stability, and resistance to environmental damage, while extending the current strength levels, which are shown by existing alloys, to higher temperatures.
With an interest in moving from steam to supercritical CO2 as the working fluid in advanced energy systems, it is important to study the mechanical response of structural alloys to CO2-containing ...environments. MARBN-type 9Cr martensitic steel was originally developed for application in boilers for supercritical and ultra-supercritical power plants where the steam temperature reaches 650 °C. In this research, a MARBN-type 9Cr martensitic steel designed and manufactured at NETL was creep tested in a gaseous CO2 environment (i.e., 0.1 MPa at 650 °C), and the results are directly compared to creep tests conducted in air. It was found that environmentally-assisted cracking facilitated by carbide formation beneath the growing oxide accelerated failure in gaseous CO2. This work indicates that creep-oxidation interactions in advanced martensitic steels represent an important consideration for materials selection in supercritical CO2 power cycles. Furthermore, this work confirms that more oxidation-resistant alloys will be required for the highest temperature portions of these systems.
•MARBN 9%Cr steel was creep tested in CO2 and air environments•CO2 environment severely reduced creep life•A complex interaction between carburization and environmentally assisted cracking was responsible for the creep detriment
The potential of high-entropy alloys (HEAs) to meet or exceed austenitic stainless steel performance with the additional benefit of improved hot corrosion/oxidation resistance makes FCC HEAs ...attractive for use in energy applications. While shorter-term creep tests have been reported in the literature on HEAs, not all methodologies utilize repeatable techniques. This manuscript reports on over 23,500 accumulated hours of tensile creep testing with adherence to ASTM standards on a melt-solidified ingot of CoCrFeNiMn HEA converted to wrought plate using conventional thermo-mechanical processing techniques. The typical standard creep analyses are reported, i.e., Larson–Miller parameter, Monkman–Grant relationship, activation energy for creep, and creep stress exponents were calculated and compared to previously reported short-term creep tests. Additionally, characteristics of creep fracture and microstructural evolution are reported with cursory dislocation mechanisms investigated.
Current research shows that high-entropy alloys can offer superior oxidation resistance compared to more traditional austenitic stainless steels with equivalent tensile mechanical performance. While ...many reports have been published on creep of CoCrFeNiMn, few focus on the CoCrFeNi family of low- to medium-entropy alloys. In this manuscript, uniaxial tensile creep test results for more than 46,000 accumulated hours are presented on the equiatomic CoCrFeNi alloy. The alloy was manufactured at NETL using a vacuum induction melt solidification approach with a computationally designed homogenization cycle. After completing the homogenization cycle, the ingot was first hot-forged and then hot-rolled into 10-mm-thick plate, a product form that is relevant to many industries. Creep tests were performed in the temperature range of 600-650 °C using applied stresses from 120 to 189 MPa. This study builds upon previous results on the CoCrFeNiMn family of high-entropy alloys and offers a modicum of clarification about performance compared to small button melts by using ASTM standard test procedures and mechanical test specimens. The apparent creep activation energy and creep stress exponent were similar to those for CoCrFe medium-entropy and CoCrFeNiMn high-entropy alloys. The post-test creep microstructure showed some Cr segregation, which has also been noted for other CoCrFe alloys. The CoCrFeNi alloy also presents a double minimum or two minimum creep rate phenomena.
Here, with an interest in moving from steam to supercritical CO2 as the working fluid in advanced energy systems, it is important to study the mechanical response of structural alloys to ...CO2-containing environments. MARBN-type 9Cr martensitic steel was originally developed for application in boilers for supercritical and ultra-supercritical power plants where the steam temperature reaches 650 °C. In this research, a MARBN-type 9Cr martensitic steel designed and manufactured at NETL was creep tested in a gaseous CO2 environment (i.e., 0.1 MPa at 650 °C), and the results are directly compared to creep tests conducted in air. It was found that environmentally-assisted cracking facilitated by carbide formation beneath the growing oxide accelerated failure in gaseous CO2. This work indicates that creep-oxidation interactions in advanced martensitic steels represent an important consideration for materials selection in supercritical CO2 power cycles. Furthermore, this work confirms that more oxidation-resistant alloys will be required for the highest temperature portions of these systems.
We report that current research shows that high-entropy alloys (HEAs) can offer superior oxidation resistance compared to more traditional austenitic stainless steels with equivalent tensile ...mechanical performance. While many reports have been published on creep of CoCrFeNiMn, few focus on the CoCrFeNi family of low to medium entropy alloys. In this manuscript, uniaxial tensile creep test results for more than 46,000 accumulated hours are presented on the equiatomic CoCrFeNi alloy. The alloy was manufactured at NETL using a vacuum induction melt solidification approach with a computationally designed homogenization cycle. After completing the homogenization cycle, the ingot was first hot forged and then hot rolled into 10 mm thick plate, a product form that is relevant to many industries. Creep tests were performed in the temperature range of 600-650 °C using applied stresses from 120 to 189 MPa. This study builds upon previous results on the CoCrFeNiMn family of high-entropy alloys and offers a modicum of clarification about performance compared to small button melts by using ASTM standard test procedures and mechanical test specimens. The apparent creep activation energy and creep stress exponent were similar to those for CoCrFe medium-entropy and CoCrFeNiMn high-entropy alloys. The post-test creep microstructure showed some Cr segregation, which has also been noted for other CoCrFe alloys. The CoCrFeNi alloy also presents a double minimum or two minimum creep rate phenomena.
Metallic alloys have played essential roles in human civilization due to their balanced strength and ductility. Metastable phases and twins have been introduced to overcome the strength-ductility ...tradeoff in face-centered cubic (FCC) high-entropy alloys (HEAs). However, there is still a lack of quantifiable mechanisms to predict good combinations of the two mechanical properties. Here we propose a possible mechanism based on the parameter κ, the ratio of short-ranged interactions between closed-pack planes. It promotes the formation of various nanoscale stacking sequences and enhances the work-hardening ability of the alloys. Guided by the theory, we successfully designed HEAs with enhanced strength and ductility compared with other extensively studied CoCrNi-based systems. Our results not only offer a physical picture of the strengthening effects but can also be used as a practical design principle to enhance the strength-ductility synergy in HEAs.
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