The mechanism of high-temperature intergranular embrittlement in a nickel-aluminide intermetallic alloy has been investigated. Crack propagation rates were measured as a function of stressintensity in four-point bend specimens loaded in air at 500–760°C. Cracking and oxidation processes were examined using a variety of analytical techniques, including scanning, transmission and scanning-transmission electron microscopy, secondary-ion mass spectroscopy, and Auger-electron spectroscopy. Failure of the bend specimens occurred by stable intergranular crack growth at rates of up to 10 −4 ms −1 at 760°C. An activation energy for the process was estimated at 110 kJ mol −1, which is consistent with interfacial oxygen diffusion as the rate determining step. The crack and oxidation product morphology suggests that crack growth took place by a discontinuous step-wise mechanism, in which oxygen penetrates the grain boundary ahead of a stationary crack tip until the boundary is sufficiently embrittled to fracture locally under the prevailing stress intensity. The crack jumps forward into fresh unembrittled material and arrests, upon which the process is repeated. Mechanisms of embrittlement are discussed. Subsequent oxidation of the crack faces produces a multi-layered infill comprising a central conglomerate layer of unoxidised nickel, flanked by aluminium oxide containing sub-micron nickel particles.
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