Sebastien N Dryepondt

Effect of environment on the scale formed on oxide dispersion strengthened FeCrAl at 1050°C and 1100°C

Abstract The surface scale formed on specimens of a commercial oxide dispersion strengthened (ODS) FeCrAl alloy (PM2000) exposed for 1 and 500 h at 1050°C in dry O2, Air+10%H2O and Ar+10%H2O consisted of a two-layer α-Al2O3 structure with a columnar grain inner layer and a finer grain outer layer. The alumina scales formed in Air+10%H2O and Ar+10%H2O were slightly more than half of the thickness of the scale formed in dry O2. The same two-layer structure was also observed after exposure for 500 h at 1100°C in dry O2 and 50%CO2+50%H2O. The alumina scales formed in both atmospheres were similar in thickness. Oxides rich in Y and Ti at the gas – scale interface grew in size and number with time in each case. Using analytical transmission electron microscopy, alumina grain boundary segregation of both Y and Ti was evident near the gas interface but only Y segregation was detected near the metal interface. This difference was attributed to Ti depletion in the adjacent metal and the rapid outward flux of the smaller Ti ion through the scale.

High temperature measurements of martensitic transformations using digital holography

During thermal cycling of nickel-aluminum-platinum (NiAlPt) and single crystal iron-chromium-nickel (FeCrNi) alloys, the structural changes associated with the martensite to austenite phase transformation were measured using dual-wavelength digital holography. Real-time in situ measurements reveal the formation of striations within the NiAlPt alloy at 70°C and the FeCrNi alloy at 520°C. The results demonstrate that digital holography is an effective technique for acquiring noncontact, high precision information of the surface evolution of alloys at high temperatures.

Evaluation of Commercial and Next Generation Alumina-Forming Austenitic Foil for Advanced Recuperators

Alumina-forming austenitic (AFA) steels represent a new class of corrosion- and creep-resistance austenitic steels to enable higher temperature recuperators. Several commercial batches of the first AFA composition have been produced with different thicknesses and widths over 39cm. This commercial AFA foil was successfully folded by two manufacturers. Creep and laboratory oxidation results at 650°-800°C are presented to compare to conventional recuperator alloy performance. While this initial effort was successful, concerns with cost and ease of production suggested that a leaner AFA composition with a lower final annealing temperature would be more attractive for commercial applications. Therefore, several new AFA compositions are being evaluated in laboratory trials and compared to the initial material for down selection of a better AFA composition for commercialization.Copyright

Influence of Environment on Creep Properties of MC2 Single Crystal Superalloy at 1150°C

In order to reveal the effect of oxidation on thin blade walls, a new machine allowing tests up to 1250°C under controlled atmosphere has been designed. Creep tests were performed on MC2 single crystal superalloy at 1150°C, under hydrogenated argon and dry air, but also with a switch from one atmosphere to the other after reaching the steady state creep stage. The results point out the decrease of the minimum creep rate in case of tests performed or at least started under hydrogenated argon, compared with the value obtained under synthetic dry air. This effect of oxidation was attributed to the protective oxide scale formed under hydrogenated argon. The low growth rate of alumina layer leads to a thinner zone affected by metal consumption, which is assumed to be non bearing, and prevents from vacancy flux toward the alloy. The second point results in slowing down creep mechanisms controlled by diffusion and therefore dislocation motion and microstructure evolution. Thermogravimetric tests confirm the difference of oxidation kinetics regards to environment (hydrogenated argon and dry air). However, oxide scales have different microstructures on thermogravimetric and creep samples when tested under air.

Rumpling of Platinum Modified Aluminide Coatings during Thermomechanical Testing

The evolution in surface morphology of platinum modified nickel aluminide (Ni,Pt)Al oxidation coatings during thermo-mechanical testing has been evaluated. One type of test consisted of cyclic oxidation between an upper temperature of 1150°C and a lower temperature varying from room temperature to 1050°C. The other type of test was cycling between 1000°C/1150°C under an applied compressive stress. Profilometry using optical interferometry was used to quantify the surface “rumpling”. First and second-order statistical parameters including RMS roughness and the auto-correlation function were calculated from the profilometry measurements. The results indicate that the grain structure of the aluminide coating plays a major role in the early stages of rumpling and set its wavelength. Also, the superimposed compressive stress during thermal cycling leads to an asymmetry in the rumpling pattern with respect with the loading axis as well as cracking along the applied stress direction.

Comparison of electron beam and laser beam powder bed fusion additive manufacturing process for high temperature turbine component materials

The evolving 3D printer technology is now at the point where some turbine components could be additive manufactured (AM) for both development and production purposes. However, this will require a significant evaluation program to qualify the process and components to meet current design and quality standards. The goal of the project was to begin characterization of the microstructure and mechanical properties of Nickel Alloy X (Ni-22Cr-18Fe-9Mo) test bars fabricated by powder bed fusion (PBF) AM processes that use either an electron beam (EB) or laser beam (LB) power source. The AM materials produced with the EB and LB processes displayed significant differences in microstructure and resultant mechanical properties. Accordingly, during the design analysis of AM turbine components, the specific mechanical behavior of the material produced with the selected AM process should be considered. Comparison of the mechanical properties of both the EB and LB materials to those of conventionally processed Nickel Alloy X materials indicates the subject AM materials are viable alternatives for manufacture of some turbine components.

Field and Laboratory Evaluations of Commercial and Next-Generation Alumina-Forming Austenitic Foil for Advanced Recuperators

Alumina-forming austenitic (AFA) steels represent a new class of corrosion- and creep-resistant austenitic steels designed to enable higher temperature recuperators. Field trials are in progress for commercially rolled foil with widths over 39 cm. The first trial completed 3000 hrs in a microturbine recuperator with an elevated turbine inlet temperature and showed limited degradation. A longer microturbine trial is in progress. A third exposure in a larger turbine has passed 16,000 hrs. Furthermore, to reduce alloy cost and address foil fabrication issues with the initial AFA composition, several new AFA compositions are being evaluated in creep and laboratory oxidation testing at 650–800 °C and the results compared to commercially fabricated AFA foil and conventional recuperator foil performance.

Field and Laboratory Evaluations of Commercial and Next Generation Alumina-Forming Austenitic Foil for Advanced Recuperators

Alumina-forming austenitic (AFA) steels represent a new class of corrosion- and creep-resistant austenitic steels designed to enable higher temperature recuperators. Field trials are in progress for commercially rolled foil with widths over 39cm. The first trial completed 3,000h in a microturbine recuperator with an elevated turbine inlet temperature and showed limited degradation. A longer microturbine trial is in progress. A third exposure in a larger turbine has passed 16,000h. To reduce alloy cost and address foil fabrication issues with the initial AFA composition, several new AFA compositions are being evaluated in creep and laboratory oxidation testing at 650°–800°C and the results compared to commercially fabricated AFA foil and conventional recuperator foil performance.Copyright

Technology Implimentation Plan - ATF FeCrAl Cladding for LWR Application

Technology implimentation plan for FeCrAl development under the FCRD Advanced Fuel program. The document describes the activities required to get FeCrAl clad ready for LTR testing

New Creep-Resistant Cast Alloys with Improved Oxidation Resistance in Water Vapor at 650–800°C

Cast stainless steel CF8C-Plus (19wt.%Cr/12%Ni) has excellent creep properties, but limited oxidation resistance above 700oC in environments containing H2O. One strategy to improve the alloy oxidation performance is to increase the Cr and Ni concentration. Two new alloys, with respectively 21wt%Cr-15wt%Ni and 22wt%Cr-17.5wt%Ni were therefore developed and their long-term oxidation behavior in humid air were compared with the oxidation behavior of five other cast alloys. At 650 and 700oC, all the alloys formed internal Cr-rich nodules, and outer nodules or layers rich in Fe and Ni, but they grew a protective Cr-rich inner layer over time. At 750oC, the lower alloyed steels such as CF8C-Plus showed large metal losses, but the two new alloys still exhibited a protective oxidation behavior. The 21Cr-15Ni alloy was severely oxidized in locations at 800oC, but that was not the case for the 22Cr-17.5Ni alloy. Therefore, the two new modified alloys represent a potential operating temperature gain of respectively 50 and 100oC in aggressive environments compared with the CF8C-Plus alloy.