High Temperature Oxidation Resistance Research Articles

A Review of Research on Improving Wear Resistance of Titanium Alloys

Titanium alloy is widely used as oil drill pipe material because of its light weight, high strength, good toughness, corrosion resistance, fatigue resistance, and good process performance. However, due to its low hardness, poor wear resistance, serious oxidation at high temperature (700 °C), and difficulty in lubrication, in oil and gas field exploration and development drilling, especially in deep wells, high displacement wells, horizontal wells, and highly deviated wells, wear and tear are prone to occur. The application and development of titanium alloys are greatly limited. This paper introduces the research status of the common surface modification technologies of titanium alloys, such as laser cladding, magnetron sputtering, plasma spraying, micro arc oxidation, etc. It points out the improvement effect of various modification technologies on the wear resistance and high-temperature oxidation resistance of titanium alloys and discusses the advantages and disadvantages of various modification technologies. A proposed method for enhancing the wear resistance and high-temperature oxidation resistance of titanium alloys was finally introduced, and its potential for future development was investigated.

Comparative study on microstructure, mechanical and high temperature oxidation resistant behaviors of SLM IN718 superalloy before and after heat treatment

The microstructure, phase transformation behavior, heat treatment effects, and their impacts on the mechanical properties and high-temperature oxidation resistance of IN718 nickel-based superalloy processed by selective laser melting (SLM) both before and after heat treatment was systematically investigated. The heat treatment process involved a two-step aging at 720 °C for 8 h plus 620 °C for 10 h with a controlled slow cooling rate of 10 °C/min. Through the comprehensive use of scanning electron microscopy (SEM), X-ray diffraction (XRD), electron backscattering diffraction (EBSD), and transmission electron microscopy (TEM), the evolution of the microstructure and its mechanism of influence on material properties were revealed. The study identified the formation of γ phase, γ′ phase, γ'' phase, δ phase, and Laves phase during the SLM forming process. Heat treatment played a key role in improving the microstructure and properties of the SLM-processed alloy, with experimental results showing that the mechanical performance and high-temperature oxidation resistance were significantly enhanced after heat treatment. Specifically, the material after heat treatment exhibited a yield strength of 1472 MPa, a tensile strength of 1608 MPa, and an elongation of 9.2%, which represented increases of 76.5%, 38.4%, and 16.5% respectively, compared to the as-printed alloy. Moreover, the oxidation resistance at 1000 °C of the heat-treated samples improved significantly, with weight loss reduced from −0.17 mg/cm2 before heat treatment to −0.15 mg/cm2. Microstructural analysis further indicated that heat treatment optimized the crystal orientation, promoted the formation of more precipitated phases and reduced defects, thereby enhancing the overall performance of the material. This work provides significant scientific insights into understanding and optimizing the IN718 nickel-based superalloy processed by SLM, demonstrating the crucial role of heat treatment in improving its microstructure and properties.

Enhancing high-temperature oxidation resistance of tantalum-tungsten alloy with composite coating

The poor oxidation resistance of tantalum-tungsten alloy at high temperatures limits its development as an ideal candidate for thermal components in aerospace. In this study, a composite coating including an internal TaSi2-WSi2 layer and an external ZrB2-MoSi2-ZrSi2 layer was prepared on the surface of Ta10W alloy by combining slurry sintering and halide activated pack cementation (HAPC). The composite coating has a dense structure, and the coating samples remains intact after oxidation at 1500°C for 6 hours, while the unprotected substrate oxidizes to powder within 3 minutes. The coated samples also withstood more than 300 shock heating cycles from room temperature to 1500°C. Its notable resistance to high-temperature oxidation was ascribed to the development of a compact and uniform SiO2 oxide layer containing oxide crystals comprising ZrSiO4, ZrO2, and Ta2O5 during the oxidation process, which effectively mitigated the diffusion of oxygen into the interior of the coating.

Effects of nitrogen content on the phase composition and high-temperature steam oxidation resistance of Cr0.5Al0.5Nx (x = 0.33, 0.81, 1.23) coatings on Zry-4 alloy

Cr0.5Al0.5Nx (x = 0.33, 0.81, 1.23) coatings were deposited on Zry-4 alloy using magnetron reaction sputtering technique to investigate their application as accident-tolerant fuel materials. The effects of nitrogen (N) content on the phase composition and high-temperature steam oxidation resistance of the coatings were systematically investigated. With the increasing N content, the phase composition of the coatings is mainly transformed from Cr(Al) to the cubic-CrAlN phase, which may be due to the formation of a greater number of CrN bonds and AlN bonds. The high-N content of the Cr0.5Al0.5Nx coating can significantly enhance the high-temperature steam oxidation resistance of zirconium alloy. Compared to the bare Zr alloy, the weight gain oxidation of the Cr0.5Al0.5N1.23 coating is reduced by 45 % after oxidation at 1200 °C for 1 h. The oxide layer thickness of the bare Zry-4 alloy is as high as 350 μm, while the oxide layer thickness of the Cr0.5Al0.5N1.23 coating is only about 12 μm. The complex oxide layer structure and an internal continuous Al2O3 layer are formed, effectively preventing the inward diffusion of O2−. In addition, with the increase of N content in the coatings, the degree of interdiffusion between the coating and the substrate is weakened. The formation of α-Zr(N) layer in the Cr0.5Al0.5N1.23 coating significantly inhibits the interdiffusion between the coating and the substrate.

Enhanced oxidation resistance in Ti3AlC2 via selective self-healing

Ti3AlC2 is anticipated to be used in high temperature fields owing to its excellent dual characteristics of metal and ceramic. However, a critical challenge arises from the inevitable formation of pores within bulk Ti3AlC2 during the sintering process, which are detrimental to its oxidation resistance performance. Herein, the high temperature self-healing and selective oxidation characteristics of Ti3AlC2 are combined, and the selective self-healing of Ti3AlC2 is realized by controlling the pre-oxidation atmosphere, i.e., the pores are effectively filled with α-Al2O3. As a result, the oxidation resistance of Ti3AlC2 was significantly enhanced by 860 times. This method provides a simple and economical way to improve the high-temperature oxidation resistance of Al-containing MAX phase materials represented by Ti3AlC2.

Study on High Temperature Properties of Yttrium-Modified Aluminide Coating on K444 Alloy by Chemical Vapor Deposition

This work aims to explore a method of improving the high-temperature oxidation resistance and thermal corrosion resistance of a hollow blade of gas turbine. The yttrium-modified aluminide coating was prepared on the surface of nickel-based superalloy K444 by chemical vapor deposition (CVD). The microstructure, high temperature oxidation resistance, and thermal corrosion resistance of the modified aluminide coating deposited at 950 °C, 1000 °C, and 1050 °C were compared. The microstructure and morphology of the coatings were observed and analyzed by XRD, SEM, and EDS. The results showed that adding yttrium and changing the deposition temperature had no effect on the double-layer structure (outer layer and diffusion layer) of the coating. Compared with adding yttrium, the deposition temperature had a greater effect on the coating thickness. When the deposition temperature was 1050 °C and the deposition time was 2 h, the thickness of the yttrium-modified aluminide coating increased by 33% compared to that of a single aluminide coating. The high temperature oxidation resistance and thermal corrosion resistance of the three groups of yttrium-modified aluminide coatings are better than that of the single aluminide coating. The resistance to high temperature oxidation and hot corrosion of the yttrium-modified aluminide coating deposited at 1050 °C was better than that of yttrium-modified aluminide coating deposited at 1000 °C, and both were better than that of the modified coating deposited at 950 °C. The higher the deposition temperature, the higher the yttrium content of the coating, the faster the film-forming speed of α-Al2O3, and the better the high temperature oxidation resistance and thermal corrosion resistance of the coating.

High temperature oxidation behavior at 1250°C: A new multilayer modified silicide coating design strategy on niobium alloys

Silicide coatings have proven to be promising for improving the high-temperature oxidation resistance of niobium alloy. However, the long-term protective property of single silicide coating remains a long-time endeavor due to the deficiency of oxygen-consuming phases, as well as the self-healing ability of the protective layer. Herein, a silicide-based composite coating is constructed on niobium alloy by incorporation of nano-SiC particles for enhancing the high-temperature oxidation resistance. Isothermal oxidation results at 1250 °C for 50 h indicate that NbSi2/Nb2O5-SiO2/SiC multilayer coated sample with a low mass gain of 2.49 mg/cm2 shows an improved oxidation resistance compared with NbSi2 coating (6.49 mg/cm2). The enhanced high-temperature antioxidant performance of NbSi2/Nb2O5-SiO2/SiC multilayer coating is mainly attributed to the formation of the protective SiO2 self-healing film and the high-temperature diffusion behavior of NbSi2/substrate.

A Study on Alloy Characterizations for Long Term Service Based Effects on Materials

Materials are a core part of the development in mechanical turbines, where there is always potential for life-improvement. The demand for alloys with durability, low cost, and long service cycles are evergreen. The materials used in turbomachinery must have excellent resistance to thermal fatigue, as well as high temperature oxidation and corrosion resistance. Good creep resistance is also an important consideration, especially for large blades and multi-airfoil latter stage nozzles. Development of new alloy compositions and material characterization plays a critical role in advanced machinery evolution. In this work, some of the available characterization methods are applied to analyze and study the effect of heat treatment, service effect and aging on alloys.

Laser surface cladding of CoNiCrAlY as Bond Coat on INCONEL718 substrate for thermal barrier coating application

This study delves into laser surface cladding of CoNiCrAlY onto Inconel718 employing a 6.6 kW continuous wave diode laser with varying process parameters. The resulting microstructure, microhardness, and isothermal oxidation resistance are meticulously assessed. Laser surface cladding yields a defect free microstructure with the presence of gamma (γ), gamma prime (γ’) and beta (β) phases. There is negligible dilution at the interface with a minimum HAZ. The average microhardness of the clad zone ranges from 425 to 465 HV, increasing with increase in scan speed and decrease in power. The high temperature oxidation resistance property of the clad surface is superior to the same developed by high velocity oxy fuel spraying.

Effects of Ta and Nb on high-temperature oxidation properties of Ti-6Al-3.5Sn-4Hf-0.4Si-X alloys

In previous studies, we identified Ta and Nb as the crucial elements affecting the high-temperature oxidation resistance of titanium alloys. To investigate their impact on microstructure evolution and oxidation resistance, we employed a constant temperature oxidation method at 700°C. The results demonstrate that Ta and Nb elements effectively inhibit oxygen diffusion and adsorption on the alloy surface, promote the formation of Al2O3 in the oxide film, and enhance its density. Notably, Ti-6Al-3.5Sn-4Hf-0.4Si-3Ta alloy exhibits exceptional antioxidation performance with an oxidation weight gain of only 0.4884 mg/cm2 after 100 hours of constant temperature oxidation at 700°C, an oxide film thickness of merely 1.047 μm, and a significant proportion (36.29 %) of O atoms combined with Al in the oxide film. The statement is in line with our previous computational findings and serves as a research foundation for the advancement of high-temperature titanium alloys.

Effect of Yttrium Additions on the High-Temperature Oxidation Behavior of GH4169 Ni-Based Superalloy.

The effect of the active element yttrium and its content on the oxidation behavior of GH4169 Ni-based superalloy at extreme temperature was studied by isothermal oxidation experiments. The results show that the oxide scale of GH4169 alloy presents a multi-layer structure, in which the continuous and dense Cr2O3 oxide layer is located in the subouter layer (II layer) and the continuous Nb-rich layer is in the subinner layer (III layer). These layers can inhibit the diffusion of oxygen and alloying elements, preventing the further oxidation of the alloy. The appropriate addition of yttrium can promote the selective oxidation of Cr element, reduce the thickness of the oxide scale and the oxidation rate of the alloy, inhibit the formation of voids at the interface of the oxide scale/alloy matrix, improve the resistance of the alloy to spalling as well as the adhesion of the oxide scale, and improve the high-temperature oxidation resistance of the alloy. Of those tested, the alloy containing 0.04 wt.%Y has the lowest oxidation weight gain, the slowest oxidation rate, and less oxide scale spalling. Based on this, the effect of yttrium on the high-temperature oxidation behavior of GH4169 Ni-based superalloy and its mechanism were revealed.

Role of nitrogen and tantalum in the high-temperature oxidation behavior of AlCoCr0.5NiTaxTi(N) alloys synthesized by laser in situ synthesis

Laser cladding was used to synthesize the coatings of the AlCoCr0.5NiTaxTi (N) alloys on a Ti–6Al–4 V substrate. As the Ta content increased, the alloy evolved from columnar crystals composed of dendritic face-centered cubic (FCC)/L12 phases and interdendritic Laves phases to a eutectic structure. The high-valence state of Ta diminished oxygen vacancies in TiO2, which reduced the diffusion rate, so an appropriate Ta content improved high-temperature oxidation resistance. In the cladding process, nitrogen from the protective gas was partially dissolved in the alloy and partially formed Ti2N, both of which act as diffusion barriers for titanium, inhibiting the formation of titanium oxide and promoting the formation of continuous single aluminum oxide, thereby improving oxidation resistance at high temperatures.

A novel high-Cr CoNi-based superalloy with superior high-temperature microstructural stability, oxidation resistance and mechanical properties

A novel high-Cr CoNi-based superalloy with superior high-temperature microstructural stability, oxidation resistance and mechanical properties

The Effect of Cr Addition on the Strength and High Temperature Oxidation Resistance of Y2O3 Dispersion Strengthened Mo Composites.

Y2O3 dispersion-strengthened Molybdenum (Mo) composites were prepared by the mechanical alloying of Mo and Y powders then consolidation by spark plasma sintering. The effects of Chromium (Cr) addition (0 wt. %, 5 wt. %, 10 wt. % and 15 wt. %, respectively) on the mechanical performance and high-temperature oxidation resistance of Mo-Y2O3 were investigated. The introduction of Cr had a significant influence on the mechanical property and oxidation resistance of the Mo-Y2O3 composite. The highest bending strength reached 932 MPa when the addition of Cr content was 5 wt. % (Mo-5Cr-1Y sample). This improvement is likely attributable to the dual mechanism of grain refinement and solid solution strengthening. Moreover, the Mo-5Cr-1Y sample showed the thinnest oxide layer thickness after high-temperature oxidation tests, and exhibited the best oxidation resistance performance compared with the other samples. First principle calculation reveals that Cr could improve the Mo-MoO3 interface bonding to prevent rapid spalling of the oxide layer. Meanwhile, Cr also facilitates the formation of the dense Cr2(MoO4)3 layer on the surface, which can inhibit further oxidation.

The Microstructure and Mechanical Properties of Si3N4f/BN/SiBCN Microcomposites Fabricated by the PIP Process.

SiBCN ceramics based on SiC, BN and Si3N4 structures have good comprehensive properties such as high-temperature resistance, oxidation resistance, creep resistance and long life, which makes it one of the very promising ceramic material systems in military and aerospace fields, etc. In this study, SiBCN ceramics, as well as Si3N4f/BN/SiBCN microcomposites, were prepared by a polymer infiltration pyrolysis method using PBSZ as the polymer precursor. The PBSZ was completely ceramized by pyrolysis at 900 °C. The weight loss and elemental bonding forms of the products after the pyrolysis of the precursors hardly changed from 600 °C to 900 °C. After pyrolysis at 600 °C for 4 h and using the BN coating obtained from twice deposition as the interfacial phase, a more desirable weak interface of fiber/matrix with a binding strength of 21.96 ± 2.01 MPa can be obtained. Si3N4f/BN/SiBCN ceramic matrix microcomposites prepared under the same pyrolysis conditions have a relatively good tensile strength of 111.10 MPa while retaining a weak interface between the fibers and the matrix. The results of the study provide more theoretical and methodological support for the application of new composite structural ceramic material systems.

Machine learning-enabled prediction of high-temperature oxidation resistance for Ni-based alloys

A machine learning (ML) model was developed to predict the oxidation resistance, with the natural logarithm of the parabolic rate constant (lnkp) as the output. Five algorithms were used to training the model, revealing that backpropagation neural network and gradient boosting exhibited superior performance with an R2 of 0.908 and 0.907. The trained models were employed to predict lnkp for changes in temperature, time, and elemental compositions. At last, promising areas with slower oxidation kinetics in typical commercial alloys were predicted under the guidance of the present ML methods.

Quantification and kinetics of nitrogen mass gain during high temperature oxidation of titanium in air

Improving the high-temperature oxidation resistance of titanium alloys in air is a prerequisite for extending their use in turbojet engines. A better understanding of the role of atmospheric nitrogen is required for this purpose. Here, we studied the insertion kinetics of nitrogen in titanium at 650 °C in air up to 100 h. Moreover, the nitrogen mass gain, and its ratio over the total mass gain, were quantified as a function of the oxidation duration by using Nuclear Reaction Analysis. It was found that nitrogen inserts into titanium with a parabolic kinetics and a rate constant about 1500 times smaller than oxygen.

High-Temperature Cyclic Oxidation Behavior and Microstructure Evolution of W- and Ce-Containing 18Cr-Mo Type Ferritic Stainless Steel.

Due to the recurrent starting and stopping operations of automobiles during service, their engines' hot ends are continually subjected to high-temperature cyclic oxidation. Therefore, it is crucial to develop ferritic stainless steels with better high-temperature oxidation resistance. This study focuses on improving the high-temperature cyclic oxidation performance of 18Cr-Mo (444-type) ferritic stainless steel by alloying with high-melting-point metal W and the rare earth element Ce. For this purpose, a high-temperature cyclic oxidation experiment was designed to simulate the actual service environment and investigate the high-temperature cyclic oxidation behavior and microstructure evolution of 444-type ferritic stainless steel alloyed with W and Ce. The oxide structure and composition formed during this process were analyzed and characterized using scanning electron microscopy/energy dispersive spectroscopy (SEM-EDS) and electron probe X-ray micro-analyzer (EPMA), in order to reveal the mechanism of action of W and Ce in the cyclic oxidation process. The results show that 18Cr-Mo ferritic stainless steel alloyed with W and Ce exhibits an excellent resistance to high-temperature cyclic oxidation. The element W can promote the precipitation of the Laves phase between the matrix and the oxide film, and the small-sized Laves phase can inhibit the interfacial diffusion of oxidation reaction elements and prevent the inward growth of the oxide film. The element Ce can refine oxide particles and reduce the thickness of the oxide film. CeO2 particles within the oxide film can serve as nucleation sites for the formation of oxide particles from reactive elements, and they also contribute to pinning the oxide film, thereby enhancing its adhesion.

The negative effect of V content on high temperature oxidation resistance of austenitic stainless steels at 850 °C

The effect of V on the high-temperature oxidation performance of austenitic stainless steel has been investigated by the constant-temperature oxidation weight gain approach, while the morphology, composition and elemental distribution of the oxide film are further analyzed by scanning electron microscopy and energy dispersive spectrum, transmission electron microscope and X-ray powder diffractometer as well as X-ray photoelectron spectroscopy, revealing the mechanism of the effect of V on the high-temperature oxidation performance of austenitic stainless steel. As a result, the addition of V has a significant adverse effect on the oxidation resistance of steel. Noteworthy, vanadium pentoxide generated during the oxidation process increases the internal stress of the surface oxide layer, reduces the integrity of the oxide layer and promotes oxygen penetration into the matrix. Simultaneously, the Z-phase formed at the grain boundaries of the matrix inhibits the diffusion of Cr ions, resulting in the inability to form an effective protective layer of Cr2O3 oxidation on the surface.

Effect of sputtering time on the microstructure and properties of MAO/CoCrFeNi composite coatings on TC11 alloy

In order to further improve the wear resistance and high-temperature oxidation resistance of titanium alloys, MAO/CoCrFeNi composite coatings with different sputtering times were prepared on TC11 alloy by micro-arc oxidation combined with radio frequency magnetron sputtering. The microstructure and phase composition of the composite coatings were investigated by scanning electron microscope and X-ray diffractometer. The wear performance at different temperature and high-temperature oxidation resistance of the composite coatings were studied. The results showed that as the sputtering time increases, the phase structure of composite coatings were all FCC phase, and the number of micropore on the composite coatings decreased; At room temperature, since the film thickness is proportional to the hardness, and higher hardness is conducive to the reduction of actual contact area between coating and grinding ball, so the composite coatings sputtered for 6 h had the narrowest wear scar width and the smallest wear weight loss, and its wear mechanisms were oxidative wear and adhesive wear; At 673 K, since the softening of the abrasive chips played a lubricating role, the composite coatings sputtered for 4 h produced the most abrasive chips, so it had the narrowest wear scar width and the smallest wear weight loss, and the wear mechanisms were mainly oxidative wear and adhesive wear, with slight abrasive wear; The composite coatings sputtered for 6 h was still tightly bonded to the substrate after oxidation at 1000 K, and its weight gain is smaller than TC11, which indicated that it has the best high-temperature oxidation resistance.