Alloy Design for Additive Manufacturing: Early-Stage Oxidation of Nickel-Based Superalloys

Joseph N. Ghoussoub; Satoshi Utada; Fernando Pedraza; William J.B. Dick-Cleland; Yuanbo T. Tang; Roger C. Reed

doi:10.1007/s11661-022-06860-6

Alloy Design for Additive Manufacturing: Early-Stage Oxidation of Nickel-Based Superalloys

Joseph N. Ghoussoub^*, Satoshi Utada, Fernando Pedraza, William J.B. Dick-Cleland, Yuanbo T. Tang, Roger C. Reed

^*Corresponding author for this work

Research output: Contribution to journal › Article › peer-review

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Abstract

This body of work aims to inform alloy design for additive manufacturing by investigating the early-stage oxidation behavior of Ni-based superalloys processed by laser-powder bed fusion. The oxidation of 14 Ni-based superalloys—some novel and some heritage—at 1000 °C for 24 hours is studied through thermo-gravimetric analysis. The mass gain, oxide layer thickness, oxide scale composition, and depletion γ' zone size are measured. The influence of the alloy composition on these variables is assessed in order to elucidate how increasingly processable and oxidation resistant alloys can be developed. The alloy compositions with Al content greater than 9 at. pct form continuous Al₂O₃ scales at 1000 °C and display markedly lower parabolic rate constants, mass gain, oxide layer thickness, and γ' depletion zone size. The alloys of lesser Al content have reduced oxidation resistance and formed oxide scales of predominantly Cr₂O₃. Alloys with Ti content of 2.7 at. pct and greater formed Ti-rich oxide phases in their oxide scales as well as TiN subscale. A trade-off between alloy processability and oxidation resistance is identified, dictated by the deleterious effect of Al content on the ductility dip and the benefit of Al for oxidation resistance. A property space along the pareto front is highlighted which is ideal for having oxidation resistance and processability.

Original language	English
Pages (from-to)	1721–1729
Number of pages	9
Journal	Metallurgical and Materials Transactions A
Volume	54
Early online date	8 Nov 2022
DOIs	https://doi.org/10.1007/s11661-022-06860-6
Publication status	Published - May 2023

Bibliographical note

Acknowledgments:
The financial support of this work by Alloyed Ltd. as well as The Natural Sciences and Engineering Research Council of Canada (NSERC) in the Chemical, Biomedical and Materials Science Engineering division Award Number 532410. The authors acknowledge funding from Innovate UK, under Project Number 104047, specifically the Materials and Manufacturing Division.

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Cite this

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title = "Alloy Design for Additive Manufacturing: Early-Stage Oxidation of Nickel-Based Superalloys",

abstract = "This body of work aims to inform alloy design for additive manufacturing by investigating the early-stage oxidation behavior of Ni-based superalloys processed by laser-powder bed fusion. The oxidation of 14 Ni-based superalloys—some novel and some heritage—at 1000 °C for 24 hours is studied through thermo-gravimetric analysis. The mass gain, oxide layer thickness, oxide scale composition, and depletion γ' zone size are measured. The influence of the alloy composition on these variables is assessed in order to elucidate how increasingly processable and oxidation resistant alloys can be developed. The alloy compositions with Al content greater than 9 at. pct form continuous Al2O3 scales at 1000 °C and display markedly lower parabolic rate constants, mass gain, oxide layer thickness, and γ' depletion zone size. The alloys of lesser Al content have reduced oxidation resistance and formed oxide scales of predominantly Cr2O3. Alloys with Ti content of 2.7 at. pct and greater formed Ti-rich oxide phases in their oxide scales as well as TiN subscale. A trade-off between alloy processability and oxidation resistance is identified, dictated by the deleterious effect of Al content on the ductility dip and the benefit of Al for oxidation resistance. A property space along the pareto front is highlighted which is ideal for having oxidation resistance and processability.",

author = "Ghoussoub, {Joseph N.} and Satoshi Utada and Fernando Pedraza and Dick-Cleland, {William J.B.} and Tang, {Yuanbo T.} and Reed, {Roger C.}",

note = "Acknowledgments: The financial support of this work by Alloyed Ltd. as well as The Natural Sciences and Engineering Research Council of Canada (NSERC) in the Chemical, Biomedical and Materials Science Engineering division Award Number 532410. The authors acknowledge funding from Innovate UK, under Project Number 104047, specifically the Materials and Manufacturing Division.",

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doi = "10.1007/s11661-022-06860-6",

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AU - Dick-Cleland, William J.B.

AU - Tang, Yuanbo T.

AU - Reed, Roger C.

N1 - Acknowledgments: The financial support of this work by Alloyed Ltd. as well as The Natural Sciences and Engineering Research Council of Canada (NSERC) in the Chemical, Biomedical and Materials Science Engineering division Award Number 532410. The authors acknowledge funding from Innovate UK, under Project Number 104047, specifically the Materials and Manufacturing Division.

PY - 2023/5

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N2 - This body of work aims to inform alloy design for additive manufacturing by investigating the early-stage oxidation behavior of Ni-based superalloys processed by laser-powder bed fusion. The oxidation of 14 Ni-based superalloys—some novel and some heritage—at 1000 °C for 24 hours is studied through thermo-gravimetric analysis. The mass gain, oxide layer thickness, oxide scale composition, and depletion γ' zone size are measured. The influence of the alloy composition on these variables is assessed in order to elucidate how increasingly processable and oxidation resistant alloys can be developed. The alloy compositions with Al content greater than 9 at. pct form continuous Al2O3 scales at 1000 °C and display markedly lower parabolic rate constants, mass gain, oxide layer thickness, and γ' depletion zone size. The alloys of lesser Al content have reduced oxidation resistance and formed oxide scales of predominantly Cr2O3. Alloys with Ti content of 2.7 at. pct and greater formed Ti-rich oxide phases in their oxide scales as well as TiN subscale. A trade-off between alloy processability and oxidation resistance is identified, dictated by the deleterious effect of Al content on the ductility dip and the benefit of Al for oxidation resistance. A property space along the pareto front is highlighted which is ideal for having oxidation resistance and processability.

AB - This body of work aims to inform alloy design for additive manufacturing by investigating the early-stage oxidation behavior of Ni-based superalloys processed by laser-powder bed fusion. The oxidation of 14 Ni-based superalloys—some novel and some heritage—at 1000 °C for 24 hours is studied through thermo-gravimetric analysis. The mass gain, oxide layer thickness, oxide scale composition, and depletion γ' zone size are measured. The influence of the alloy composition on these variables is assessed in order to elucidate how increasingly processable and oxidation resistant alloys can be developed. The alloy compositions with Al content greater than 9 at. pct form continuous Al2O3 scales at 1000 °C and display markedly lower parabolic rate constants, mass gain, oxide layer thickness, and γ' depletion zone size. The alloys of lesser Al content have reduced oxidation resistance and formed oxide scales of predominantly Cr2O3. Alloys with Ti content of 2.7 at. pct and greater formed Ti-rich oxide phases in their oxide scales as well as TiN subscale. A trade-off between alloy processability and oxidation resistance is identified, dictated by the deleterious effect of Al content on the ductility dip and the benefit of Al for oxidation resistance. A property space along the pareto front is highlighted which is ideal for having oxidation resistance and processability.

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Alloy Design for Additive Manufacturing: Early-Stage Oxidation of Nickel-Based Superalloys

Abstract

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