Unveiling the Re effect in Ni-based single crystal superalloys

Improvement of Hydrogen-Resistant Gas Turbine Engine Blades: Single-Crystal Superalloy Manufacturing Technology

This paper presents the results of an analysis of resistance to hydrogen embrittlement and offers solutions and technologies for manufacturing castings of components for critical applications, such as blades for gas turbine engines (GTEs). The values of the technological parameters for directional crystallization (DC) are determined, allowing the production of castings with a regular dendritic structure of the crystallization front in the range of 10 to 12 mm/min and a temperature gradient at the crystallization front in the range of 165-175 °C/cm. The technological process of making GTE blades has been improved by using a scheme for obtaining disposable models of complex profile castings with the use of 3D printing for the manufacture of ceramic molds. The ceramic mold is obtained through an environmentally friendly technology using water-based binders. Short-term tensile testing of the samples in gaseous hydrogen revealed high hydrogen resistance of the CM-88 alloy produced by directed crystallization technology: the relative elongation in hydrogen at a pressure of 30 MPa increased from 2% for the commercial alloy to 8% for the experimental single-crystal alloy.

Effect of the Addition of Re on the Microstructure and Phase Composition of Haynes 282: Ab Initio Modelling and Experimental Investigation of Additively Manufactured Specimens

Interactions in a multicomponent Ni-Cr-Mo-Al-Re model alloy were determined by ab initio calculations in order to investigate the Re doping effect on Haynes 282 alloys. Simulation results provided an understanding of short-range interactions in the alloy and successfully predicted the formation of a Cr and Re-rich phase. The Haynes 282 + 3 wt% Re alloy was manufactured using the additive manufacturing direct metal laser sintering (DMLS) technique, in which the presence of the (Cr₁₇Re₆)C₆ carbide was confirmed by an XRD study. The results provide useful information about the interactions between Ni, Cr, Mo, Al, and Re as a function of temperature. The designed five-element model can lead to a better understanding of phenomena that occur during the manufacture or heat treatment of modern, complex, multicomponent Ni-based superalloys.

Rhenium-Based Electrocatalysts for Water Splitting

Due to the contamination and global warming problems, it is necessary to search for alternative environmentally friendly energy sources. In this area, hydrogen is a promising alternative. Hydrogen is even more promising, when it is obtained through water electrolysis operated with renewable energy sources. Among the possible devices to perform electrolysis, proton exchange membrane (PEM) electrolyzers appear as the most promising commercial systems for hydrogen production in the coming years. However, their massification is affected by the noble metals used as electrocatalysts in their electrodes, with high commercial value: Pt at the cathode where the hydrogen evolution reaction occurs (HER) and Ru/Ir at the anode where the oxygen evolution reaction (OER) happens. Therefore, to take full advantage of the PEM technology for green H2 production and build up a mature PEM market, it is imperative to search for more abundant, cheaper, and stable catalysts, reaching the highest possible activities at the lowest overpotential with the longest stability under the harsh acidic conditions of a PEM. In the search for new electrocatalysts and considering the predictions of a Trasatti volcano plot, rhenium appears to be a promising candidate for HER in acidic media. At the same time, recent studies provide evidence of its potential as an OER catalyst. However, some of these reports have focused on chemical and photochemical water splitting and have not always considered acidic media. This review summarizes rhenium-based electrocatalysts for water splitting under acidic conditions: i.e., potential candidates as cathode materials. In the various sections, we review the mechanism concepts of electrocatalysis, evaluation methods, and the different rhenium-based materials applied for the HER in acidic media. As rhenium is less common for the OER, we included a section about its use in chemical and photochemical water oxidation and as an electrocatalyst under basic conditions. Finally, concluding remarks and perspectives are given about rhenium for water splitting.

Hot Tensile Deformation Behavior and Constitutive Models of GH3230 Superalloy Double-Sheet

In this paper, the hot tensile deformation of a GH3230 superalloy double-sheet was conducted under deformation temperatures ranging from 1123~1273 K and strain rates ranging from 0.001~0.2 s^-1. The flow behavior of the GH3230 superalloy double-sheet was analyzed in detail. The hot tensile deformation process of the GH3230 superalloy double-sheet includes four stages of elastic deformation, strain hardening, steady state and fracture. The true stress decreases with the increasing deformation temperature and decreasing strain rate. The variation of the strain rate sensitivity index and strain hardening index with processing parameters were discussed. The average apparent activation energy for hot tensile deformation is 408.53 ± 46.96 kJ·mol^-1. A combined Johnson-Cook and Hensel-Spittle model considering the couple effect of strain hardening, strain rate hardening and thermal softening was established to describe the hot tensile behavior of the GH3230 alloy double-sheet. Compared to Johnson-Cook model and Hensel-Spittle model, this model has the highest predicting accuracy. The average absolute relative error of true stress between the experimental and the predicted is only 2.35%.

Revisiting stress-corrosion cracking and hydrogen embrittlement in 7xxx-Al alloys at the near-atomic-scale

The high-strength 7xxx series aluminium alloys can fulfil the need for light, high strength materials necessary to reduce carbon-emissions, and are extensively used in aerospace for weight reduction purposes. However, as all major high-strength materials, these alloys can be sensitive to stress-corrosion cracking (SCC) through anodic dissolution and hydrogen embrittlement (HE). Here, we study at the near-atomic-scale the intra- and inter-granular microstructure ahead and in the wake of a propagating SCC crack. Moving away from model alloys and non-industry standard tests, we perform a double cantilever beam (DCB) crack growth test on an engineering 7xxx Al-alloy. H is found segregated to planar arrays of dislocations and to grain boundaries that we can associate to the combined effects of hydrogen-enhanced localised plasticity (HELP) and hydrogen-enhanced decohesion (HEDE) mechanisms. We report on a Mg-rich amorphous hydroxide on the corroded crack surface and evidence of Mg-related diffusional processes leading to dissolution of the strengthening η-phase precipitates ahead of the crack.

Phase stability and the interface structure of a nanoscale Si crystallite in Al-based alloys

An atomic-scale understanding of the role of strain on the microstructural properties of nanoscale precipitates will be helpful to explore the precipitation behavior as well as the structure-property relationships in crystalline multi-phase systems. Nanoscale Si precipitates are formed in Al-based alloys prepared by selective laser melting. The phase structure and the nature of heterointerface have been characterized using advanced electron microscopy. The nanocrystalline Si mainly contains two polymorphs, diamond-cubic Si (DC-Si) and 4H hexagonal Si (4H-Si). Heteroepitaxy occurs at the DC-Si(111)/Al(100) and 4H-Si(0001)/Al(100) interfaces in terms of a coincidence-site lattice model. The nanocrystalline Si undertakes tensile strain superposed by the matrix through heterointerfaces, facilitating the formation of 4H-Si in the nanoscale crystallite, which provides a strategy for designing Si polymorphic materials by strain engineering.

On the fabrication of atom probe tomography specimens of Al alloys at room temperature using focused ion beam milling with liquid Ga ion source

In this work, a simple rectangular milling technique was demonstrated to prepare needle shape atom probe tomography (APT) specimens from Al alloys by focused-ion-beam (FIB) milling using Ga⁺ ions at room temperature. Ga has high miscibility in Al owing to which electropolishing technique is preferred over Ga⁺ ion FIB instruments for the fabrication of APT specimens. Although, site specific sample preparation is not possible by the electropolishing technique. This led to the motivation to demonstrate a new rectangular milling technique using Ga⁺ FIB instrument that resulted a significant reduction of Ga⁺ ion impregnation into the specimens. This is attributed to the reduction of milling time (<30 s at 30 kV acceleration voltage) and the use of lower currents (<0.3 nA) compared to the conventional annular milling method. The yield of specimens during field evaporation in APT was also significantly increased from around 8 million ions to more than 86 million ions due to the avoidance of Ga⁺ ion embrittlement. Therefore, the currently demonstrated rectangular milling technique can be used to prepare APT specimens from Al-alloys and obtained accurate compositions of matrix, phases, and hetero-phase interfaces with Ga < 0.1 at%.

Compositions of Gamma and Gamma Prime Phases in an As-Cast Nickel-Based Single Crystal Superalloy Turbine Blade

The core and the interdendritic regions of an as-cast nickel based single crystal turbine blade were observed by electron microscopy to understand the microstructural development during an investment casting process. The dendrite core region shows an irregular morphology of gamma prime in gamma due to a relatively short casting time, which prevented the development of gamma prime expected in a solution heat-treated microstructure. By comparison, the interdendritic region comprises three different regions composed of: several elongated gamma prime particles, relatively tiny and irregular gamma prime, and gamma prime with relatively regular morphology. The chemical analysis of these phases showed that, regardless of the analysis point in the core or the interdendritic region, almost the same compositions were acquired in the regular type of gamma and gamma prime phases. This result suggests that if the gamma prime forms in the gamma matrix, the composition of gamma prime is almost uniform regardless of the region and prevailing general chemical composition. In contrast, the composition of the elongated gamma prime in the interdendritic region was slightly different depending on the analysis point even within the same elongated particle.

Phase-Field Modeling of Chemoelastic Binodal/Spinodal Relations and Solute Segregation to Defects in Binary Alloys

Microscopic phase-field chemomechanics (MPFCM) is employed in the current work to model solute segregation, dislocation-solute interaction, spinodal decomposition, and precipitate formation, at straight dislocations and configurations of these in a model binary solid alloy. In particular, (i) a single static edge dipole, (ii) arrays of static dipoles forming low-angle tilt (edge) and twist (screw) grain boundaries, as well as at (iii) a moving (gliding) edge dipole, are considered. In the first part of the work, MPFCM is formulated for such an alloy. Central here is the MPFCM model for the alloy free energy, which includes chemical, dislocation, and lattice (elastic), contributions. The solute concentration-dependence of the latter due to solute lattice misfit results in a strong elastic influence on the binodal (i.e., coexistence) and spinodal behavior of the alloy. In addition, MPFCM-based modeling of energy storage couples the thermodynamic forces driving (Cottrell and Suzuki) solute segregation, precipitate formation and dislocation glide. As implied by the simulation results for edge dislocation dipoles and their configurations, there is a competition between (i) Cottrell segregation to dislocations resulting in a uniform solute distribution along the line, and (ii) destabilization of this distribution due to low-dimensional spinodal decomposition when the segregated solute content at the line exceeds the spinodal value locally, i.e., at and along the dislocation line. Due to the completely different stress field of the screw dislocation configuration in the twist boundary, the segregated solute distribution is immediately unstable and decomposes into precipitates from the start.

The hidden structure dependence of the chemical life of dislocations

Dislocations are one-dimensional defects in crystals, enabling their deformation, mechanical response, and transport properties. Less well known is their influence on material chemistry. The severe lattice distortion at these defects drives solute segregation to them, resulting in strong, localized spatial variations in chemistry that determine microstructure and material behavior. Recent advances in atomic-scale characterization methods have made it possible to quantitatively resolve defect types and segregation chemistry. As shown here for a Pt-Au model alloy, we observe a wide range of defect-specific solute (Au) decoration patterns of much greater variety and complexity than expected from the Cottrell cloud picture. The solute decoration of the dislocations can be up to half an order of magnitude higher than expected from classical theory, and the differences are determined by their structure, mutual alignment, and distortion field. This opens up pathways to use dislocations for the compositional and structural nanoscale design of advanced materials.

Critical Raw Materials Saving by Protective Coatings under Extreme Conditions: A Review of Last Trends in Alloys and Coatings for Aerospace Engine Applications

Several applications, where extreme conditions occur, require the use of alloys often containing many critical elements. Due to the ever increasing prices of critical raw materials (CRMs) linked to their high supply risk, and because of their fundamental and large utilization in high tech products and applications, it is extremely important to find viable solutions to save CRMs usage. Apart from increasing processes’ efficiency, substitution, and recycling, one of the alternatives to preserve an alloy and increase its operating lifetime, thus saving the CRMs needed for its manufacturing, is to protect it by a suitable coating or a surface treatment. This review presents the most recent trends in coatings for application in high temperature alloys for aerospace engines. CRMs’ current and future saving scenarios in the alloys and coatings for the aerospace engine are also discussed. The overarching aim of this paper is to raise awareness on the CRMs issue related to the alloys and coating for aerospace, suggesting some mitigation measures without having the ambition nor to give a complete overview of the topic nor a turnkey solution.