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Dispersoid Distribution and Microstructure in Fe-Cr-Al Ferritic Oxide Dispersion-Strengthened Alloy Prepared by Friction Consolidation

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Abstract

INCOLOY® MA956 is a ferritic oxide dispersion-strengthened alloy manufactured by mechanical alloying followed by hot extrusion in vacuum-sealed cans or by degassing and hot isostatic pressing. This could be followed by a tailored heat treatment sequence in order to obtain a desired microstructure and to allow the oxide dispersion to precipitate. Three different oxides, responsible for the high-temperature mechanical strength, have been observed in this alloy: Y4Al2O9, YAlO3, and Y3Al5O12. Their sizes range from just a few to hundreds of nanometers. In this work, mechanically alloyed MA956 powder was consolidated via friction consolidation, a single-step and potentially cheaper processing alternative. Three fully dense compacts were produced. The compacts exhibited a refined, equiaxed grain structure with grain sizes smaller than 10 µm and the desired oxide dispersion. YAlO3 and Y3Al5O12 were identified by scanning electron microscopy, energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction. The size distribution of precipitates above 50 nm showed a direct proportionality between average precipitate size and grain size. The total energy input during processing was correlated with the relative amount of each of the oxides in the disks: the higher the total processing energy input, the higher the relative amount of Y3Al5O12 precipitates. The elemental composition of the oxide precipitates was also probed individually by EDS, showing an aluminum enrichment trend as precipitates grew in size.

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Authors and Affiliations

  1. University of South Carolina, 300 Main St, Columbia, SC, 29208, USA

    Djamel Kaoumi (Associate Professor) & Anthony P. Reynolds (Professor)

  2. Pacific Northwest National Laboratory, 902 Battelle Blvd, Richland, WA, 99352, USA

    David Catalini (Materials Engineer) & Glenn J. Grant (Senior Scientist)

Authors
  1. David Catalini
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  2. Djamel Kaoumi
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  3. Anthony P. Reynolds
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  4. Glenn J. Grant
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Correspondence to Djamel Kaoumi.

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Manuscript submitted December 12, 2012.

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Catalini, D., Kaoumi, D., Reynolds, A.P. et al. Dispersoid Distribution and Microstructure in Fe-Cr-Al Ferritic Oxide Dispersion-Strengthened Alloy Prepared by Friction Consolidation. Metall Mater Trans A 46, 4730–4739 (2015). https://doi.org/10.1007/s11661-015-3059-1

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