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Solid-State Deposit-Induced Corrosion of a Second-Generation Nickel-Based Superalloy Caused by CaO and CaSO4 Deposits

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Abstract

The goal of this research project was to provide a fundamental understanding of CaO-and CaSO4-induced corrosion in second-generation Ni-based single-crystal superalloys and to develop a lab-scale test procedure, which accurately replicates corrosion observed in field-exposed components. Secondary and transmission electron microanalyses were used to characterize the corrosion of field-exposed components taken from commercial aviation turbines. It was found that the field-exposed components had been attacked by internal oxidation-sulfidation. Isothermal laboratory-scale experiments at 900 and 1150 °C in air were conducted on superalloy coupons deposited with either CaO or CaSO4 to assess the extents and modes of solid-state corrosion caused by either deposit. A novel bi-thermal test procedure was then developed which effectively replicated the internal oxidation-sulfidation found in the field-exposed components. It was determined that compositional and microstructural changes to the alloy subsurface caused by CaSO4-induced corrosion at elevated temperatures made the alloy susceptible to internal oxidation at lower temperatures.

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Funding

Funding support of this study by the Office of Naval Research (grant N00014-17–1-2916), Dr. David Shifler. Program Manager, is greatly appreciated.

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Author notes

  1. Patrick T. Brennan

    Present address: GE Research, Niskayuna, NY, USA

  2. Doug Konitzer

    Present address: University of Pittsburgh, Pittsburgh, PA, USA

  3. Michael Brennan

    Present address: Blue Origin, Seattle, WA, USA

Authors and Affiliations

  1. GE Aviation, Cincinnati, OH, USA

    Doug Konitzer & Michael Brennan

  2. University of Pittsburgh, Pittsburgh, PA, USA

    Patrick T. Brennan & Brian Gleeson

Authors
  1. Patrick T. Brennan
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  2. Doug Konitzer
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  3. Michael Brennan
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  4. Brian Gleeson
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Correspondence to Patrick T. Brennan.

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Brennan, P.T., Konitzer, D., Brennan, M. et al. Solid-State Deposit-Induced Corrosion of a Second-Generation Nickel-Based Superalloy Caused by CaO and CaSO4 Deposits. Oxid Met 98, 43–63 (2022). https://doi.org/10.1007/s11085-022-10105-7

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  • DOI: https://doi.org/10.1007/s11085-022-10105-7

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