Effect of Interface Form on Creep Failure and Life of Dissimilar Metal Welds Involving Nickel-Based Weld Metal and Ferritic Base Metal

For dissimilar metal welds(DMWs)involving nickel-based weld metal(WM)and ferritic heat resistant steel base metal(BM)in power plants,there must be an interface between WM and BM,and this interface suffers mechanical and microstructure mismatches and is often the rupture location of premature failure.In this study,a new form of WM/BM interface form,namely double Y-type interface was designed for the DMWs.Creep behaviors and life of DMWs containing double Y-type interface and conventional I-type interface were compared by finite element analysis and creep tests,and creep failure mechanisms were investigated by stress-strain analysis and microstructure characterization.By applying double Y-type interface instead of conventional I-type interface,failure location of DMW could be shifted from the WM/ferritic heat-affected zone(HAZ)interface into the ferritic HAZ or even the ferritic BM,and the failure mode change improved the creep life of DMW.The interface premature failure of I-type interface DMW was related to the coupling effect of microstructure degradation,stress and strain concentrations,and oxide notch on the WM/HAZ interface.The creep failure of double Y-type interface DMW was the result of Type IV fracture due to the creep voids and micro-cracks on fine-grain boundaries in HAZ,which was a result of the matrix softening of HAZ and lack of precipitate pinning at fine-grain boundaries.The double Y-type interface form separated the stress and strain concentrations in DMW from the WM/HAZ interface,preventing the trigger effect of oxide notch on interface failure and inhibiting the interfacial microstructure cracking.It is a novel scheme to prolong creep life and enhance reliability of DMW,by means of optimizing the interface form,decoupling the damage factors from WM/HAZ interface,and then changing the failure mechanism and shifting the failure location.

Recent advances in nickel-based catalysts in eCO_(2)RR for carbon neutrality

The excessive use of nonrenewable energy has brought about serious greenhouse effect.Converting CO_(2) into high-value-added chemicals is undoubtedly the best choice to solve energy problems.Due to the excellent cost-effectiveness and dramatic catalytic performance,nickel-based catalysts have been considered as the most promising candidates for the electrocatalytic CO_(2) reduction reaction(eCO_(2)RR).In this work,the electrocatalytic reduction mechanism of CO_(2) over Ni-based materials is reviewed.The strategies to improve the eCO_(2)RR performance are emphasized.Moreover,the research on Ni-based materials for syngas generation is briefly summarized.Finally,the prospects of nickel-based materials in the eCO_(2)RR are provided with the hope of improving transition-metal-based electrocatalysts for eCO_(2)RR in the future.

Effect of the capsule on deformation and densification behavior of nickel-based superalloy compact during hot isostatic pressing

The Shima yield criterion used in finite element analysis for nickel-based superalloy powder compact during hot isostatic pressing(HIP) was modified through uniaxial compression experiments. The influence of cylindrical capsule characteristics on FGH4096M superalloy powder compact deformation and densification behavior during HIP was investigated through simulations and experiments. Results revealed the simulation shrinkage prediction fitted well with the experimental shrinkage including a maximum shrinkage error of 1.5%. It was shown that the axial shrinkage was 1.7% higher than radial shrinkage for a cylindrical capsule with the size of ∮50 mm × 100 mm due to the force arm difference along the axial and radial direction of the capsule. The stress deviated from the isostatic state in the capsule led to the uneven shrinkage and non-uniform densification of the powder compact. The ratio of the maximum radial displacement to axial displacement increased from0.47 to 0.75 with the capsule thickness increasing from 2 to 4 mm. The pressure transmission is related to the capsule thickness, the capsule material performance, and physical parameters in the HIP process.

Morphological evolution of γ'precipitates in a nickel-based superalloy during various solution treatments

The morphological evolution of the γ' phase in nickel-based superalloy жc6y during various solution heat treatments was investigated. The significant changes of the γ' precipitates were observed in the solution-treated samples. The coarsening and dissolution of γ' phase simulta-neously occurred at intermediate temperatures. In some areas, the primary precipitates became blunt and the adjacent ones were intercon-nected with each other via a diffuse neck, indicating a coarsening process of the primary γ' population. The coarsening was dominated by the precipitate agglomeration mechanism (PAM) rather than by the well-known Ostwald ripening mechanism. In other areas, the partial dissolu-tion of the γ' precipitates began to occur, spreading gradually from dendrite cores to interdendritic regions. In addition, a flower-like γ' struc-ture was developed during the subsolvus solution treatments. The observable long filaments composed of erraticly shaped precipitates were caused by the heterogeneous nucleation of the cooling precipitates during water quenching.

Coarsening behavior of γ' particles in a nickel-base superalloy

The coarsening behavior of γ' particles in a nickel-base superalloy FGH95 was investigated by means of experimental observations and growth kinetics calculations. The results show that when aging at 1000,1080 and 1140°C for different times,the relation of average particle size to time obeys the cube law ( a /2)3= kt,where k is 15.49 × 103,77.5 × 103 and 230.04 × 103 nm3/min,respectively. The particle size distributions are better fit to the LSW theoretical distributions when aging at 1000°C within 1440 min. The activation energy for γ' particles coarsening is determined to be 288.20±1.79 kJ/mol,which correlates well to the diffusion activation energies of Al,Ti,and Nb in the nickel matrix. This indicates that the coarsening of γ' particles is controlled by the diffusion of Al,Ti,and Nb in the nickel matrix. The coarsening kinetics of γ' particles in FGH95 is predicted as rt 3 = 1.04 × 10 16t exp[-(288200 ± 1790 )/RT].

RAFTING PREDICTION CRITERION FOR NICKEL-BASE SINGLE CRYSTALS UNDER MULTIAXIAL STRESSES AND CRYSTALLOGRAPHIC ORIENTATION DEPENDENCE OF CREEP BEHAVIOR

1.IntroductionIthasbeenacceptedwidelythatthecrystallographicorientationdependenceofcreepbehaviordependsontheanisotropicraftingofac'-particles.Duringcreepdeformationtheinitiallycubical7'-particlescoarsendirectionally,formingrafting.Morphologychangesof...

Na_2SO_4- and NaCl- Induced Hot Corrosion Behaviors of a Nickel-Base Superalloy with Aluminide Diffusion Coating

Hot-corrosion behaviors of nickel-base superalloy and aluminide diffusion coating have been investigated in conditions of contents of Na2SO4 and NaCI molten salts at 900℃ by means of XRD and SEM. Hot-corrosion scale of the superalloy and aluminide diffusion coating were analyzed and their surface morphologies were observed. The results demonstrate that both coated and uncoated specimens are not susceptible to various contents of NaCI. That may be resulted from the AI2O3 scale formation. Growth stress was characterized by the formation of convoluted scales.

Research progress on selective laser melting processing for nickel-based superalloy

Selective laser melting(SLM),an additive manufacturing process mostly applied in the metal material field,can fabricate complex-shaped metal objects with high precision.Nickel-based superalloy exhibits excellent mechanical properties at elevated temperatures and plays an important role in the aviation industry.This paper emphasizes the research of SLM processed Inconel 718,Inconel 625,CM247LC,and Hastelloy X,which are typical alloys with different strengthening mechanisms and operating temperatures.The strengthening mechanism and phase change evolution of different nickel-based superalloys under laser irradiation are discussed.The influence of laser parameters and the heat-treatment process on mechanical properties of SLM nickel-based superalloys are systematically introduced.Moreover,the attractive in-dustrial applications of SLM nickel-based superalloy and printed components are presented.Finally,the prospects for nickel-based superalloy materials for SLM technology are presented.

Creep feed grinding induced gradient microstructures in the superficial layer of turbine blade root of single crystal nickel-based superalloy

The service performance of the turbine blade root of an aero-engine depends on the microstructures in its superficial layer.This work investigated the surface deformation structures of turbine blade root of single crystal nickel-based superalloy produced under different creep feed grinding conditions.Gradient microstructures in the superficial layer were clarified and composed of a severely deformed layer(DFL)with nano-sized grains(48–67 nm)at the topmost surface,a DFL with submicron-sized grains(66–158 nm)and micron-sized laminated structures at the subsurface,and a dislocation accumulated layer extending to the bulk material.The formation of such gradient microstructures was found to be related to the graded variations in the plastic strain and strain rate induced in the creep feed grinding process,which were as high as 6.67 and 8.17×10^(7)s^(−1),respectively.In the current study,the evolution of surface gradient microstructures was essentially a transition process from a coarse single crystal to nano-sized grains and,simultaneously,from one orientation of a single crystal to random orientations of polycrystals,during which the dislocation slips dominated the creep feed grinding induced microstructure deformation of single crystal nickel-based superalloy.

Effect of Heat Treatment on High Temperature Stress Rupture Strength of Brazing Seam for Nickel-base Superalloy

In order to enhance the high-temperature stress rupture strength of brazing seam by heat treatment, it was diffusion treated, then solution heat treated, and finally aging treated. The microstructure of brazing seam especially morphology of y’ phase and boride was observed and the strength of brazing seam was measured in this process. The results show that heat treatment can enhance high- temperature stress rupture strength by improving the microstructure of brazing seam. The strength of brazing seam after solution heat treatment decreases in comparison with that only after diffusion treatment while aging treatment after solution heat treatment increases the strength of brazing seam.

Effect of TiC addition on the microstructure and wear resistance of induction brazed nickel-based coating in air

The nickel-based coating with different TiC addition was fabricated onto 45 steel substrate by using induction brazed technology in air.The effect of TiC addition on the microstructure and wear resistance of induction brazing coating was studied.The results show that the microstructure of brazing coating is strengthened and refined by adding TiC.With the increase of the amount of TiC added,the amount of TiC in the Ni-based matrix is increased,and the matrix structure is obviously refined.This is because the high melting point TiC particles can be used as heterogeneous nucleation cores,thus refining the Ni based matrix structure.Moreover,the wear resistance of brazing coating is improved due to the addition of TiC.

Nickel-base superalloys for USC power plants

The advanced ultra-supercritical power plants of the future will utilize steam pressures and temperatures that are too high for traditional ferritic steels,thus requiring austenitic materials.Older nickel-base superalloys such as 263 and 617 were initially evaluated under the European THERMIE project beginning in the 1990s.An entirely new age-hardened alloy 740 which possesses exceptional fireside corrosion resistance and creep strength was also developed for boiler tubing capable of serving at 700C.Subsequently,interest in the USA considered other product forms such as steam header piping and steam turbine forgings for service as high as 760C.A more stable and weldable alloy version now called 740H was developed to meet these more demanding conditions.This paper summarizes the current status of work on alloys 740 and 740H.

A critical review on nickel-based cathodes in rechargeable batteries

The 3d transition-metal nickel(Ni)-based cathodes have long been widely used in rechargeable batteries for over 100 years,from Ni-based alkaline rechargeable batteries,such as nickel-cadmium(Ni-Cd)and nickel-metal hydride(Ni-MH)batteries,to the Ni-rich cathode featured in lithium-ion batteries(LIBs).Ni-based alkaline batteries were first invented in the 1900s,and the well-developed Ni-MH batteries were used on a large scale in Toyota Prius vehicles in the mid-1990s.Around the same time,however,Sony Corporation commercialized the first LIBs in camcorders.After temporally fading as LiCoO_(2) dominated the cathode in LIBs,nickel oxide-based cathodes eventually found their way back to the mainstreaming battery industry.The uniqueness of Ni in batteries is that it helps to deliver high energy density and great storage capacity at a low cost.This review mainly provides a comprehensive overview of the key role of Ni-based cathodes in rechargeable batteries.After presenting the physical and chemical properties of the 3d transition-metal Ni,which make it an optimal cationic redox center in the cathode of batteries,we introduce the structure,reaction mechanism,and modification of nickel hydroxide electrode in Ni-Cd and Ni-MH rechargeable batteries.We then move on to the Ni-based layered oxide cathode in LIBs,with a focus on the structure,issues,and challenges of layered oxides,LiNiO_(2),and LiNi_(1−x−y)Co_(x)Mn_(y)O_(2).The role of Ni in the electrochemical performance and thermal stability of the Ni-rich cathode is highlighted.By bridging the“old”Ni-based batteries and the“modern”Ni-rich cathode in the LIBs,this review is committed to providing insights into the Ni-based electrochemistry and material design,which have been under research and development for over 100 years.This overview would shed new light on the development of advanced Ni-containing batteries with high energy density and long cycle life.

Effects of the Solution Treatment on Microstructural Evolution, Mechanical Properties, and Fracture Mechanism of Nickel-Based GH4099 Superalloy

Grain growth, mechanical properties, and fracture mechanism of nickel-based GH4099 superalloy are investigated using heat treatments, tensile tests, optical microscopy (OM), and scanning electron microscopy (SEM) with energy dispersive X-ray spectroscopy (EDS). The OM observation shows that the matrix grains (γ-grains) undergo an apparent growth during the solution treatment. The grain size diameter increases from 100 to 174 μm when the solution temperature rises from 1100℃ to 1160℃ for 30 min. When the holding time increases from 15 to 60 min at 1140℃, the grain size diameter increases from 140 to 176 μm, indicating that the γ-grain growth is more sensitive to temperature than time. Standard deviation, Sv, and the grain size distribution are utilized to characterize the microstructural uniformity. To predict the grain size more accurately, we develop the grain growth kinetics and find that the growth index is close to 5. The yield strength (Rp0.2), tensile strength (Rm), and ductility (Af) are also measured. It is found that the effect decreases in the order cooling rate, solution temperature, time. Rp0.2 reduces by 47% with the increase in the cooling rate from 1℃ to 8000℃/min, while both strength and ductility exhibit little changes with time. The SEM results show that the fracture surfaces have typical mixed brittle and ductile characteristics when specimens are subjected to water quenching and air cooling. However, a complete brittle fracture occurs under furnace cooling conditions. The EDS analysis indicates that the brittle γ' (Ni3Ti) phase precipitates around the γ-grain boundary during the slow cooling process, which is the main factor yielding the complete brittle fracture. Finally, the optimal solution treatment scheme for the GH4099 superalloy is proposed—a temperature of 1140℃ for 30 min followed by air cooling.

Hot Cracking Susceptibility of 800H and 825 Nickel-Base Superalloys during Welding via Spot Varestraint Test

Hot cracking susceptibility of fillers 52 and 82 in 800H and 825 nickel-base superalloys was discussed using the Spot Varestraint test.The fillers of 52 and 82 were added into nickel-base superalloys via a gas tungsten arc welding(GTAW).Experimental results showed that the hot cracking sensitivity of the nickel-base superalloys with filler at high temperature was lower than that without filler.The hot cracking sensitivity had a slight effect when the filler 82 was added.The total length of crack was increased,the liquid-solid(L-S)two-phase range is higher so that the hot cracking susceptibility will be raised.The morphologies of cracks included the intergranular crack in the molten pool,molten pool of solidification cracking,heat-affected zone of intergranular cracks,and transgranular crack in the heat-affected zone.

NICKEL-BASE ALLOY SHEET ALLOYS USED IN AEROSPACE APPLICATIONS

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Thermal desorption characteristic of helium ion irradiated nickel-base alloy

The nickel-base alloy is one of the leading candidate materials for generation IV nuclear reactor pressure vessel.To evaluate its stability of helium damage and retention,helium ions with different energy of 80 keV and 180 keV were introduced by ion implantation to a certain dose(peak displacement damage 1-10 dpa).Then thermal desorption spectroscopy(TDS)of helium atoms was performed to discuss the helium desorption characteristic and trapping sites.The desorption peaks shift to a lower temperature with increasing dpa for both 80 keV and 180 keV irradiation,reflecting the reduced diffusion activation energy and faster diffusion within the alloy.The main release peak temperature of 180 keV helium injection is relatively higher than that of 80 keV at the same influence,which is because the irradiation damage of 180 keV,helium formation and entrapment occur deeper.The broadening of the spectra corresponds to different helium trapping sites(He-vacancies,grain boundary)and desorption mechanisms(different Hen Vm size).The helium retention amount of 80 keV is lower than that of 180 keV,and a saturation limit associated with the irradiation of 80 keV has been reached.The relatively low helium retention proves the better resistance to helium bubbles formation and helium brittleness.

High temperature creep-rupture features of nickel-base single crystal superalloy

The creep and rupture behavior of a nickel-base single crystal superalloy with [001] orientation was investigated at temperature of 10001040℃ and stress in the range of 150320MPa. The creep features and microstructure were studied by means of the measurement of creep curves and TEM observation. The results show that all creep curves exhibit a short primary and a dominant accelerated creep stage. From the creep parameters and TEM observations, it is suggested that the primary deformation mechanism has a change from precipitatation shearing by pairs of dislocation in the high applied stress region to dislocations climb around the γ′ particles in the low applied stress region. Furthermore, the detailed failure process and fracture surfaces were analyzed by SEM observation.

Microstructure and mechanical properties of nickel-based superalloy fabricated by laser powder-bed fusion using recycled powders

Evaluating the recyclability of powders in additive manufacturing has been a long-term challenge.In this study,the microstructure and mechanical properties of a nickel-based superalloy fabricated by laser powder-bed fusion(LPBF)using recycled powders were investigated.Re-melted powder surfaces,satellite particles,and deformed powders were found in the recycled powders,combined with a high-oxygencontent surface layer.The increasing oxygen content led to the formation of high-density oxide inclusions;moreover,printing-induced cracks widely occurred and mainly formed along the grain boundaries in the as-built LPBF nickel-based superalloys fabricated using recycled powders.A little change in the Si or Mn content did not increase the hot cracking susceptibility(HCS)of the printed parts.The changing aspect ratio and the surface damage of the recycled powders might contribute to increasing the crack density.Moreover,the configuration of cracks in the as-built parts led to anisotropic mechanical properties,mainly resulting in extremely low ductility vertical to the building direction,and the cracks mainly propagated along the cellular boundary owing to the existence of a brittle precipitation phase.

Spin and spin-orbit coupling effects in nickel-based superalloys:A first-principles study on Ni_(3)Al doped with Ta/W/Re

Heavy elements(X=Ta/W/Re)play an important role in the performance of superalloys,which enhance the strength,anti-oxidation,creep resistance,and anti-corrosiveness of alloy materials in a high-temperature environment.In the present research,the heavy element doping effects in FCC-Ni(γ)and Ni_(3)Al(γ')systems are investigated in terms of their thermodynamic and mechanical properties,as well as electronic structures.The lattice constant,bulk modulus,elastic constant,and dopant formation energy in non-spin,spin polarized,and spin-orbit coupling(SOC)calculations are compared.The results show that the SOC effects are important in accurate electronic structure calculations for alloys with heavy elements.We find that including spin for bothγandγ'phases is necessary and sufficient for most cases,but the dopant formation energy is sensitive to different spin effects,for instance,in the absence of SOC,even spin-polarized calculations give 1%to 9%variance in the dopant formation energy in our model.Electronic structures calculations indicate that spin polarization causes a split in the metal d states,and SOC introduces a variance in the spin-up and spin-down states of the d states of heavy metals and reduces the magnetic moment of the system.