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Growth Stresses in Thermally Grown Oxides on Nickel-Based Single-Crystal Alloys

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Abstract

Growth stresses that develop in α-Al2O3 scale that form during isothermal oxidation of three Ni-based single crystal alloys have been studied to elucidate their role in coating and substrate degradation at elevated temperatures. Piezospectroscopy measurements at room temperature indicate large room temperature compressive stresses in the oxides formed at 1255 K or 1366 K (982 °C or 1093 °C) on the alloys, ranging from a high of 4.8 GPa for René N4 at 1366 K (1093 °C) to a low of 3.8 GPa for René N5 at 1255 K (982 °C). Finite element modeling of each of these systems to account for differences in coefficients of thermal expansion of the oxide and substrate indicates growth strains in the range from 0.21 to 0.44 pct at the oxidation temperature, which is an order of magnitude higher than the growth strains measured in the oxides on intermetallic coatings that are typically applied to these superalloys. The magnitudes of the growth strains do not scale with the parabolic oxidation rate constants measured for the alloys. Significant spatial inhomogeneities in the growth stresses were observed, due to (i) the presence of dendritic segregation and (ii) large carbides in the material that locally disrupts the structure of the oxide scale. The implications of these observations for failure during cyclic oxidation, fatigue cycling, and alloy design are considered.

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Acknowledgments

The authors are grateful for the support of ONR Grant Number 5 N00014-14-1-0618 (TMP) and N00014-14-1-0618 (AHH). Useful discussions with A. Suzuki, D. Konitzer, D. Clarke, V. Tolpygo, and D. Lipkin are acknowledged.

Author information

Authors and Affiliations

  1. Materials Department, University of California Santa Barbara, Santa Barbara, USA

    Luke H. Rettberg (Graduate Student), Britta Laux (Development Engineer), Ming Y. He (Research Scientist) & Tresa M. Pollock (Materials Department Chair)

  2. Eaton Corporation, Euclid, OH, USA

    David Hovis (Metallurgist)

  3. Department of Materials Science and Engineering, Case Western Reserve University, Cleveland, USA

    David Hovis (Metallurgist) & Arthur H. Heuer (Professor)

  4. Siemens AG, Berlin, Germany

    Britta Laux (Development Engineer)

Authors
  1. Luke H. Rettberg
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  2. Britta Laux
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  3. Ming Y. He
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  4. David Hovis
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  5. Arthur H. Heuer
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  6. Tresa M. Pollock
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Corresponding author

Correspondence to Luke H. Rettberg.

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Manuscript submitted April 13, 2015.

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Rettberg, L.H., Laux, B., He, M.Y. et al. Growth Stresses in Thermally Grown Oxides on Nickel-Based Single-Crystal Alloys. Metall Mater Trans A 47, 1132–1142 (2016). https://doi.org/10.1007/s11661-015-3273-x

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