THE INFLUENCE OF ENVIRONMENT ON FATIGUE AND FRACTURE OF IRON ALUMINIDES

This paper reviews recent research on embrittlement of iron aluminides brought about by exposure to moisture or hydrogen. The tensile and fatigue crack growth behavior of several Fe-Al alloys, ranging in aluminum content from 16 to 35a%, is described. It will be shown that tensile ductility and fatigue crack growth behavior are dependent on type and degree of long range order, grain structure, temperature and environment. Environments studied include vacuum,oxygen, hydrogen gas, electrolytically charged hydrogen and moist air. All cases of embrittlement are ultimately traceable to the interaction of hydrogen with the lattice.

Effects of Microstructure on the Tensile, Fracture Toughness and Fatigue Behaviour of Gamma Titanium Aluminides

The effects of microstructure on the deformation and fracture behaviour of two-phase TiAl alloys were investjgated under monotonic and cyclical loading conditions, over a range of temperatu res.The tensile behaviour is analyzed for deformation temperatures between RT and 950℃, Fracture resistance behaviour and toughening mechanisms at RT and 800℃ are analyzed. and the inverse relationship botween ductility and toughness is explained using the crack initiation toughness. The preliminary results of load-controlled fatigue behaviour at 800℃ are interpreted using the tensile behaviour because deformation structure and fracture modes are similar under these two loading conditions

MICROSTRUCTURAL EVOLUTION AND MECHANISMS OF SUPERPLASTICITY IN LARGE GRAINED IRON ALUMINIDES

The superplastic behavior has been found in Fe 3Al and FeAl alloys with grain sizes of 100～600 μm. The large grained Fe 3Al and FeAl alloys exhibit all deformation characteristics of conventional fine grain size superplastic alloys. However, superplastic behavior was found in large grained iron aluminides without the usual prerequisites for the superplasticity of a fine grain size and grain boundary sliding. The metallographic examinations have shown that average grain size of large grained iron aluminides decreased during superplastic deformation. Transmission electron microscopy (TEM) observations have shown that there were a great number of subgrain boundaries which formed a network and among which the proportion of low and high angle boundaries increased with the increase of strain. The observed superplastic phenomenon is explained by continuous recovery and recrystallization. During superplastic deformation, an unstable subgrain network forms and these subboundaries absorb gliding dislocations and transform into low and high angle grain boundaries. A dislocation gliding and climb process accommodated by subboundary sliding, migration and rotation, allows the superplastic flow to proceed.

INTERMEDIA TETEMPERATURE STRESS ANOMALY IN B_2 ALLOYS: WITH SPECIAL ATTENTION TO THE CASE OF IRON ALUMINIDES

The iron aluminides show anomalous stress peaks at temperatures of the order of 400～600 ℃, irrespective of whether the crystal structure is B2 type or DO 3 type. Such features will be examined on the basis of thermally activated dislocation processes, considering the influence of test parameters such as temperature and strain rate, and material parameters such as crystal composition and orientation. Detailed analyses of deformation modes by slip step studies, transmission electron microscopy examinations of dislocation structures, and texture studies will also be considered. Observations of dislocation structures are clearly of great interest for suggesting the possible models of deformation, but suffer from two major weaknesses: the post mortem structures in samples deformed at high temperature may not be the same as those producing plasticity; almost all possible hypotheses for strengthening can find support from such observations, since almost all imaginable dislocation configurations can be found with sufficient diligence by the researcher. Strengthening at intermediate temperatures in DO 3 and B2 ordered iron aluminides will be analysed here, making combined use of observations of deformation structures and examinations of the influence of varying the deformation parameters.

Effect of niobium alloying level on the oxidation behavior of titanium aluminides at 850°C

This work addresses the alloying of titanium aluminides used in aircraft engine applications and automobiles. The oxidation resistance behavior of two titanium aluminides of α2 ＋ γ （Ti3Al ＋ TiAl） and orthorhombic Ti2NbAl, recognized as candidates for high-temperature applications, was investigated by exposure of the alloys for 100 h in air. Thus, oxidation resistance was expressed as the mass gain rate, whereas surface aspects were analyzed using scanning electron microscopy in conjunction with energy-dispersive X-ray spectroscopy, and the type of oxidation products was analyzed by X-ray diffraction and Raman spectroscopy. The orthorhombic Ti2NbAl alloy was embrittled, and pores and microcracks were formed as a result of oxygen diffusion through the external oxide layer formed during thermal oxidation for 100 h.

A New Process for Titanium Aluminides Production from TiO_2

This paper describes a new process for producing titanium aluminides, in particular TiAl, from TiO2 raw material. On the basis of obtained results, the non-completed reaction of TiO2 with Al and Ca in a special reaction vessel results in the production of granulates of titanium aluminides especially Ti3Al and other Ti- Al phases as the metallic product and Ca12Al14O33 as the non-metallic product. By adding KClO4 in the mixture, a nearly completed reaction can be carried out. The products of this reaction are titanium aluminide particularly TiAl as the metallic part and CaAl4O7 （grossite） as the non-metallic slag part. Both product and slag are produced in a separated form. This process, called KRH-method is described in this article. The scanning electron microscopic microstructure of metallic part of the product shows different phases： the matrix phase is TiAI, where the needle form precipitation is TiAl2 and the plate form precipitation includes TiAI and Ti3Al phases. The microstructure of the remelted metallic part indicates dendritic phase with a lamellar structure comprising of TiAl and Ti3Al phases. The interdendritic phase of TiAI is also seen.

Deformability and microstructure transformation of PM TiAl alloy prepared by pseudo-HIP technology

Microstructures and deformation properties of Ti-46Al-(Cr,Nb,W,B)alloy consolidated by pseudo-HIP technology were investigated.The results show that the pseudo-HIP temperature has a significant effect on microstructures.When the sintering temperature is 1 100℃,the microstructure of as-pseudo-HIPped alloy is similar to that of the prealloyed powder and the interfaces of these powder particles are still discernible,but a nearγmicrostructure appears in particles.Increasing the pressing temperature to 1 200℃develops successfully a homogeneous and fine-grained duplex microstructure.A typically fully lamellar microstructure with residualβphase is developed at 1 300℃.The compact exhibits excellent deformation properties at elevated temperatures. When the compression temperature is higher than 1 100℃,high quality products without cracks can be obtained even if the engineering compression strain is up to 0.8 at strain rates of 10-2-10-3s-1.It can be established that the mechanical twinning and matrix deformation due to ordinary dislocation slip/climb contribute to the whole hot deformation.

INTERMETALLIC ALLOYS AND COMPOSITES FOR THE 21ST CENTURY: A BASIC ENERGY SCIENCES PROGRAM OF THE U. S. DEPARTMENT OF ENERGY

Progress has been made in intermetallic alloys over the past decade and a half, but intermetallics remain a relatively unexplored class of materials for energy applications. Hence, they offer considerable opportunities both for scientific research on fundamental structural property processing relationships and for technological development. The Department of Energy supports a program of scientific research on intermetallic alloys such as the nickel and iron aluminides and is establishing new research efforts in silicides and Laves phases through the program of the Division of Materials Sciences, of the Office of Basic Energy Sciences. Areas of research include theory and materials simulation, microalloying, high resolution sudies of structure and composition, mechanical properties, point defects and dislocation mechanics, phase transformations, and processing. Research is conducted through programs at the Department of Energy National Laboratories and through grants to academic and industrial researchers.Research results from Division of Materials Sciences programs have provided the basis and transportation. In addition, a cooperative effort between research groups has been established as a project on intermetallic materials under the Center of Excellence in Synthesis and Processing of Advanced Materials.

Fabrication of in situ Ti_2AlN/TiAl Composites by Reaction Hot Pressing and Their Properties

Ti2AIN/TiAI composites with different volume fractions of reinforcement were successfully fabricated by hot-pressing sintering method （reaction hot pressing） using Ti, Al and TiN powders as starting materials. The synthesis process includes four stages： first, the reactions between Al and Ti powers and between Al and TiN powders respectively occur and result in TiAl3 phase; secondly, AI powders in the sample are exhausted; the remaining Ti cores react with TiAl3 layer to form Ti-Al intermetallics; moreover, a few Ti2AlN particles precipitate from the TiAl3 phase; thirdly, Ti-Al intermetallics react with the remaining Ti cores to form Ti3Al and TiAl phases. TiAl phase and original TiN powers are in direct contact each other; finally, the residual TiN powers react with TiAl phase and result in a plenty of TizAIN phase. Compared with TiAl matrix, the hardness, elastic modulus and high-temperature compressive strength of Ti2AlN/TiAl composite are improved obviously and they are all enhanced with increasing the volume fraction of Ti2AlN phase.

Microstructures of mechanically activated Ti-46at.%Al powders and spark plasma sintered ultrafine TiAl alloy

Powder of Ti-46at.%Al was synthesized through mechanical activation （MA） for different milling times, and the 16 h MAed powder was sintered by using a spark plasma sintering （SPS） process at different sintering temperatures. The XRD profiles showed that the MAed Ti-46at,%Al powder for 12, 16, and 20 h contained initial α-Ti and Al phases, and that the SPSed TiAl alloys contained the gamma TiAl and α2-Ti3Al phases. The TEM showed two different types of regions in the 16 h MAed Ti-46at.%Al powder. One type consisted of only Al with a grain size about 80 nm, and the other type a mixture of Al and Ti with a grain size of 30 nm. According to the optical micrographs of MA-SPSed samples, the alloys sintered at higher temperatures showed a coarser microstructure. In the case of the 1473 Ksintering, typical duplex structures （（α2 ＋γ） lamella and γ phases） with interlamellar spacings of 50-400 nm and the grain size either less than 100 nm, or 1000 nm were observed.

CREEP OF A POLYCRYSTALLINE NEAR γ-TiAl Alloy WITH A LAMELLAR MICROSTRUCTURE

Creep of a polycrystalline near γ-TiAl alloy in two fully lamellar conditions is presented. A lamellar structure with fine interface spacing and planar grain boundaries provides improved creep resistance. The lamellar structure with wide interface spacing and interlocked grain boundaries has <1/2 the creep life, five times the minimum strain rate and greater tertiary strain.Creep strain is accommodated by dislocation motion in soft grains, but the strain rate is controlled by hard grains. The resistance to fracture is controlled by the grain boundary morphology, with planar boundaries causing intergranular fracture.To maximize the creep resistance of near γ-TiAl with a lamellar microstructure requires narrow lamellar interface spacing and interlocked lamellae along grain boundaries.

Solidification structures of high niobium containing TiAl alloys

To understand the effect of alloy stoichiometry on the microstructural development and mechanical behavior of γ-TiAl- based materials, it is necessary to have a determination of the phase relationships for the TiAl alloy system near the γ phase field. Cast structures and phases of Ti-(43-47)Al-8Nb-(1-2)Mn (at%) alloys have been studied by using scanning electron microscope and X-ray diffraction. Their solidification path and microstructure development during the solidification were analyzed. The experimental results show that the alloys with different Al contents form different macrostructures and microstructural morphologies. This indi- cates that the solidification paths are different with different Al contents. The alloy with 43Al forms equiaxed grain structure, and the solidification path is as follows: L —? L+β —? β —? α+β —> α+β cores —> O2+γ+B2 cores. Whereas the alloy with 47Al forms colum- nar grain structure, and the solidification path is as follows: L —> L+β —? α+β+L —? α+γ+β cores —> tXj+γ+BZ cores. The p phase is their primary solid phase and can be retained to ambient temperature. The alloy with 43Al solidifies completely into β phase. The peritectic reactions L+P —> α and L+α-? γ appear when the Al content increases to 47Al.

Bulk Al–Al_3Zr composite prepared by mechanical alloying and hot extrusion for high-temperature applications

Bulk Al/Al_3Zr composite was prepared by a combination of mechanical alloying(MA) and hot extrusion processes. Elemental Al and Zr powders were milled for up to 10 h and heat treated at 600℃ for 1 h to form stable Al_3Zr. The prepared Al_3Zr powder was then mixed with the pure Al powder to produce an Al–Al_3Zr composite. The composite powder was finally consolidated by hot extrusion at 550℃. The mechanical properties of consolidated samples were evaluated by hardness and tension tests at room and elevated temperatures. The results show that annealing of the 10-h-milled powder at 600℃ for 1 h led to the formation of a stable Al_3Zr phase. Differential scanning calorimetry(DSC) results confirmed that the formation of Al_3Zr began with the nucleation of a metastable phase, which subsequently transformed to the stable tetragonal Al_3Zr structure. The tension yield strength of the Al-10wt%Al_3Zr composite was determined to be 103 MPa, which is approximately twice that for pure Al(53 MPa). The yield stress of the Al/Al_3Zr composite at 300℃ is just 10% lower than that at room temperature, which demonstrates the strong potential for the prepared composite to be used in high-temperature structural applications.

MICROSTRUCTURE AND MECHANICAL PROPERTIES OF Fe_3Al BASED ALLOYS

The promise for industrial applications offered by iron aluminides is today restricted by insufficient ductility at room temperature and mediocre strength and creep resistance at high temperatures. The tendency to embrittlement in the presence of hydrogen or water vapour limits the ductility even more. The atomic arrangements in binary and alloyed variants are examined here and related to the difficulties of dislocation propagation at room and at high temperatures. In this way the influence of intrinsic structure and alloying modifications on mechanical behaviour can be understood. Possibilities for further improving properties through structure control are considered.

PRECIPITATION BEHAVIOR OF Co PHASES IN B2-ORDERED(Ni,Co)Al COMPOUND

The precipitation behavior of Co phases in B2-ordered (Ni,Co)Al has been investigated in terms of transmission electron microscopy. Fine precipitation of fcc-Co occurs in (Ni,Co)Al by aging at temperature over 973K. The orientation relationship between the fee-Co precipitates and the B2-(Ni,Co)Al matrix follows the Kurdjumow-Sachs (K-S) orientation relation. But when the aging temperature is under 873K the Co precipitates have a hcp crystal structure. The orientation relationship between the hep-Co precipitates and the B2-(Ni,Co)Al matrix follows the Burgers orientation relation. (Ni,Co)Al is hardened appreciably by the fine precipitation of both the fee-Co and hep-Co phases. The temperature dependence of the yield strength of precipitate-containing BS-ordered (Ni, Co)Al was investigated by compression tests over the range of 298-1273K. The fine precipitation of Co phases enhances greatly the low and intermediate temperature yield strength. When the deformation temperature was over 87SK, the strength of precipitate-containing (Ni, Co)Al is comparable to ternary dual-phase (Ni,Co)Al+Ni3Al alloy.

Microstructures and Properties of FeAl-Fe_3AlC_(0.5) Composites Prepared by SHS Casting

FeAl composites with 21, 37 and 50 wt pct Fe3AlC0.5 were fabricated by a self-propagating high temperature synthesis （SHS） casting. Phases and microstructures were analyzed by X-ray diffraction （XRD） and scanning electron microscopy （SEM）. Microhardness and bending strength of the composites were measured. The composites with 21 and 50 wt pct Fe3AlC0.5 mainly consisted of FeAl and FesAlC0.5 phases, whereas the composite with 37 wt pct Fe3AlC0.5 was composed of FeAl, Fe3AlC0.5 and graphite phases. The bonding of the reinforcement and the matrix was good. Hardness and bending strength of the composite with 37 wt pct Fe3AlC0.5 was lower than those of the 21 and 50 wt pct composites owing to the presence of the soft graphite phase.

Strain-induced Microstructural Changes and Effects of Alloying Elements for Fe_3Al-based Alloys

The strain-induced microstructural changes of Fe3Al-based alloys during room temperature deformation and high temperature creep were investigated. The results illustrated the strain-induced disor dering occured during room temperature deformation. Creep strain could induced two opposite processes, which are strain-induced disordering and creep recovery-induced reordering. These two opposite creep induced processes during creep result in reducing the influence of primary microstructure on the rupture life.

Microstructure and cellular transition characteristic of Ti-42Al-3Nb-1Mo-0.1B alloy

The microstructure and cellular transition characteristics of an intermetallic Ti-42Al-3Nb-1Mo-0.1B (at.%) alloy were investigated.The as-cast microstructure of the alloy is mainly composed of (α2+γ) lamellar structure and (β+γ) mixture structure,which distributes along the boundaries of the lamellar colonies.In order to study the phase transformation of lamellar structure at aging temperature,a two-step heat treatment was carried out.After the first step of annealing treatment at 1,260 °C,the microstructure with relatively finer lamellar space and (γ+β/B2) mixture structure is obtained.Aging treatment,as the second heat treatment step,has significant influence on the microstructure,attributing to a cellular reaction of α2+γ→γ+β.With the increase of aging temperature,the (α2+γ) lamellar structure continues to dissolve,whereas the contents of both the equiaxed γ and β/B2 grains continuously increase.Besides,the orientation of lamellae α2,equiaxed γ and equiaxed β/B2 in the cellular transition region follows a specific relationship of {0-11}β<1-11>β//{0001}α2<2-1-10>α2//{1-11}γ<-101>γ.

Fabrication of Dense Ultrafine TiAl Alloys by Spark Plasma Synthesis from Mechanically Activiated Powders

Powder of Ti-46at%Al alloy was synthesized through mechanical activation（MA） and then sintered and concurrently consolidated in a short sintering time of 900 s by using a spark plasma sintering（SPS） process. The XRD and SEM profiles show that the microstructures of TiAl alloys contained γ TiAl and small amount α-2 Ti3Al phase, whose amount can be controlled by the sintering temperature. The compacts retained the original fine-grained fully densified bodies by avoiding an excessively high sintering temperature. The alloys sintered at higher temperature with this process showed a coarser microstructure. So it is possible to produce dense nanostructured TiAl alloys by mechanically activated spark plasma sintering （MASPS） within a very short period of time.

The Synthesis and Characterization of Arc Melted Fe₁-_xAl_xAlloys

The paper presents correlation study on a series of Fe1-xAlx alloy samples prepared by arc melting. All the samples show crystalline structure, irrespective of the Al content and are textured mainly along (110) direction. The particle size decreases rapidly with x particularly after x > 0.3. The corresponding magnetic measurements were obtained at room temperature using a VSM, with a maximum applied field of 14 kOe. The results show that the ferromagnetic state of the samples disappears with x, and becomes paramagnetic for alloys with x ≥ 0.4. It is also found that coercivity (Hc) and resistivity increase with x. The results were interpreted in terms of continuous change in their electronic structure i.e. overlap of the electron wave functions of the magnetic atoms with the Al electron wave function.