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Oxidation Behavior of Ni-Based Oxide Dispersion-Strengthened Alloy Fabricated by Direct Energy Deposition at 1100 °C

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Abstract

Additive manufacturing (AM) produced Ni-based oxide dispersion-strengthened (ODS) alloy is promising for fabricating intrinsic structural parts under high-temperature operating condition, while little effort has been focused on the oxidation behavior of such alloys by AM. In this study, cyclic oxidation behavior and microstructure of additively manufactured Ni-based ODS alloy were evaluated up to 1100 °C for 2040 thermal cycles. The oxide layer and microstructure were characterized at various thermal cycles using scanning electron microscope (SEM), transmission electron microscope (TEM), and x-ray diffractometer (XRD), respectively. The results showed ultrafine Y-rich particles (<20 nm) in both as-printed and oxidized ODS coupons. In the early oxidation stages, continuous Al2O3 formed underneath oxide mixture of Cr2O3 and NiO with oxide spallation of Cr2O3 and NiO due to the thermal expansion mismatch at later oxidation stages. Uniform oxide dispersion of yttria contributed the stability of Al2O3 layer and thus preserved γ′ phase in the alloy substrate as well as fine grain structure by reducing elemental diffusion and blocking dislocation movement.

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Acknowledgments

The authors express their gratitude for the financial support provided by the United States Department of Energy [Award Number: DE-FE0031277] and the support received from the Instrumentation Seed Program for Innovative Research (InSPIRe) from West Virginia University Research Corporation (WVURC) and WVU Statler College of Engineering and Mineral Resources. The authors also acknowledge the utilization of West Virginia University Shared Research Facilities (SRF). Special thanks are extended to Dr. Qiang Wang and Dr. Marcela Redigolo at WVU SRF for their valuable assistance with XRD and TEM tests, respectively.

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  1. Department of Mechanical, Materials, and Aerospace Engineering, West Virginia University, Morgantown, WV, 26506, USA

    Changyu Ma & Bruce S. Kang

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Ma, C., Kang, B.S. Oxidation Behavior of Ni-Based Oxide Dispersion-Strengthened Alloy Fabricated by Direct Energy Deposition at 1100 °C. J. of Materi Eng and Perform (2024). https://doi.org/10.1007/s11665-024-09449-9

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