Effects of laser shock processing on θ-Al2O3 to α-Al2O3 transformation and oxide scale morphology evolution in (γ’+β) two-phase Ni-34Al-0.1Dy alloys

doi:10.1016/j.jmst.2021.09.028

Abstract

Abstract:

(γ’+β) two-phase Ni-Al is a promising high-temperature protective coating material used on Ni-base superalloys since it has good interfacial compatibility with superalloys due to the low Al content compared to single-phase β-NiAl. In this paper, we aim to improve the oxidation resistance, whereby Ni-34Al-0.1Dy, a (γ’+β) two-phase Ni-Al alloy, was treated by laser shock processing (LSP) and the oxidation behavior at 1150 °C was investigated. The results showed that after oxidation, Al₂O₃ scale formed on the original β phase of the untreated alloy with a small grain size (200-800 nm), while for the LSP-treated samples, the scale grown on the original β phase was dominantly composed of larger Al₂O₃ grains with a size of 2-3 μm. The distinction was attributed to the promotion of θ-Al₂O₃ to α-Al₂O₃ transformation induced by the LSP, because the dislocation density, as well as surface roughness, were increased during LSP treatment which can provide heterogeneous nucleation sites for α-Al₂O₃. In addition, the larger-size Al₂O₃ particles, derived from the direct conversion of needle-like θ-Al₂O₃ in the initial oxidation stage, could rapidly overspread the whole β phase surface thus reducing the scale growth rate.

Key words: Intermetallics, Laser shock processing, Oxidation, θ-Al₂O₃ to α-Al₂O₃ transformation, Morphology evolution

Bangyang Zhou, Jian He, Qijie Zhou, Hongbo Guo. Effects of laser shock processing on θ-Al₂O₃ to α-Al₂O₃ transformation and oxide scale morphology evolution in (γ’+β) two-phase Ni-34Al-0.1Dy alloys[J]. J. Mater. Sci. Technol., 2022, 109: 157-166.

Figures/Tables 17

Fig. 1. Schematic of the LSP process.

Table 1. Parameters of LSP.

Parameters	Value	Unit
Wavelength	1064	nm
Pulse duration	20	ns
Spot diameter	3	mm
Overlapping rate	50	%
Pulse energy	2-6	J

Fig. 2. The back-scattered electron image with corresponding element mappings of the as-annealed Ni-34Al-0.1Dy alloy.

Table 2. Chemical compositions of the as-annealed alloys (at.%).

	Ni	Al	Dy
β	63.78	36.22	-
γ’	73.36	26.64	-
Dy-rich phase	72.65	11.56	15.79

Fig. 3. Surface morphologies of oxide scales after 100 h cyclic oxidation at 1150 °C: (a, d) untreated sample; (b, e) LSP-2 sample; (c, f) LSP-6 sample.

Table 3. Chemical compositions of the marked areas (at.%).

	Al	Ni	O
1	53.22	0.22	46.54
2	39.59	10.49	49.87
3	49.71	0.07	50.22
4	37.06	11.58	51.35
5	47.23	5.8	46.91

Fig. 4. Cross-sectional morphologies of oxide scales after 100 h cyclic oxidation at 1150 °C: (a, d) untreated sample; (b, e) LSP-2 sample; (c, f) LSP-6 sample.

Table 4. Thickness of oxide scale (μm).

	Thickness of oxide scale
Untreated sample	5-5.6
LSP-2	3.4-4.5
LSP-6	3.5-4.8

Fig. 5. Surface morphologies of oxide scales after different isothermal oxidation time at 1150 °C: (a) untreated sample at 20 h oxidation; (b) LSP-2 sample at 20 h oxidation; (c) LSP-6 sample at 20 h oxidation; (d) untreated sample at 50 h oxidation; (e) LSP-2 sample at 50 h oxidation; (f) LSP-6 sample at 50 h oxidation.

Fig. 6. The photo-stimulated luminescence spectra of the oxide scale at 1150 °C: (a) 10 min; (b) 30 min; (c) 60 min; (d) curve of θ-Al2O3 content with the oxidation time; (e) residual stress of the oxide scale after 1 h oxidation.

Table 5. Chemical compositions of Al2O3 with different sizes (at.%).

Empty Cell	Al	Ni	O
1 (small size Al₂O₃ particles)	38.18	4.69	57.01
2 (large size Al₂O₃ particles)	43.89	0.71	55.40

Fig. 7. Mapping results of the oxide scale after 30 min oxidation at 1150 °C: (a) untreated samples; (b) LSP-2; (c) LSP-6 (For interpretation of the references to color in this figure, the reader is referred to the web version of this article).

Fig. 8. Surface morphologies of the oxide scale grown on original β phase at 1150 °C after 10 min, 30 min and 60 min, respectively.

Fig. 9. Surface morphologies of the oxide scale grown on original β phase after 5 h oxidation at 1150 °C: (a) untreated samples; (b) LSP-2; (c) LSP-6.

Fig. 10. TEM analysis of the cross-section of the samples: (a) untreated sample; (b-f) LSP-treated samples.

Fig. 11. 3D surface topography of LSP treated samples: (a) LSP-2; (b) LSP-6.

Fig. 12. Schematic diagram of morphology transformation of Al2O3 grown on original β phase.

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Effects of laser shock processing on θ-Al₂O₃ to α-Al₂O₃ transformation and oxide scale morphology evolution in (γ’+β) two-phase Ni-34Al-0.1Dy alloys

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