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Understanding the oxidation of Ni-based single crystal (SX) superalloys is significantly important because oxidation can damage the microstructure and eventually lead to failure of the alloy. Using advanced scanning/transmission electron microscopy, oxidation effects on the microstructure of a SX superalloy during heat treatment and simulated service (stress/temperature coupling) conditions are systematically investigated in order to reveal oxide microstructures and oxidation mechanisms. Heat treatment in argon results in less weight loss, thinner γ′-free layer and fewer internal oxidation than that treated in air. But the oxide layer structures and influence depths of oxidation in both atmospheres are similar. External tensile stress not only accelerates the oxidation of alloy but also affects the oxide microstructures. Moreover, stress effects on the oxidation microstructure depend on temperature. At 750 °C, Ni–Co oxides are formed on the alloy surface, followed by the inner layer of Ni–Co–Mo–Re–W oxides at the location of original γ phase under stress free condition. As the stress increases, an oxide layer mainly containing Al, Cr, Nb, Mo and Re elements is formed between the above two oxide layers. When temperature increases to 1050 °C, as applied tensile stress increases, the thickness of oxide layer increases but the structure of oxide layer is not obviously changed. [ABSTRACT FROM AUTHOR]

The cyclic oxidation behavior of fourth-generation nickel-based single crystal superalloys with 2–4 wt% Mo content were studied at 900 ℃ and 1100 ℃. At 900 ℃, with the increase of Mo content, the oxide layer accumulates more growth stress, resulting in the interface between the outer oxide layer and the inner oxide layer more prone to crack initiation. At 1100 ℃, the oxidation layer accumulates more growth stress and thermal stress, so the oxidation layer occurs large scale spalling, which is more severe in 4Mo alloy. The results show that the increase of Mo content of alloy promotes the oxidation of containing W-Re alloy, which promotes the volatilization of oxides and the spalling of oxide, decreases the protection of oxide layer, and deteriorates the oxidation resistance of the alloy. • The increase of Mo content of alloy promotes the oxidation of containing W-Re alloy. • With the increase of Mo content, the volatilization of oxides and the spalling of oxide of alloy was promoted. • Mo has more severe harm to the oxidation resistance of the alloy at higher temperature. • The alloy with 2 wt% Mo addition has the highest oxidation resistance. [ABSTRACT FROM AUTHOR]

Amorphous Al 2 O 3 coating was prepared on Ni-based single crystal superalloy via atomic layer deposition (ALD) for high temperature oxidation protection. The oxygen inward transport and outward-cation diffusion were hindered by amorphous Al 2 O 3 coating, and the coated alloy showed high oxidation resistance. The low oxygen partial pressure at the alloy/coating interface altered the alloy oxidation behavior, allowing the priority oxidation of protective Al and Cr elements. The oxidation process was controlled by the growth of Cr 2 O 3 and Al 2 O 3. The coating exhibited high spallation resistance. Degradation of the coating, the formation of NiAl 2 O 4 phase in amorphous Al 2 O 3 layer, was observed. • Amorphous Al 2 O 3 coating was proposed and prepared on Ni-based single crystal superalloy. • The amorphous Al 2 O 3 coating improved oxidation resistance and exhibited high adhesion. • The amorphous Al 2 O 3 coating altered the oxidation behavior of the alloy. • The effect mechanism of amorphous Al 2 O 3 coating on the alloy oxidation was discussed. [ABSTRACT FROM AUTHOR]

The oxidation behavior of a fourth-generation nickel-based single crystal superalloy with different heat treatments were studied at 1100 °C in air. The specimens were divided into three groups, one as-cast group, and two heat-treated groups: solution treated and fully heat treated. The elemental distribution is mainly affected by the solution temperature, the higher the solution temperature, the more uniform the distribution of elements. Heat treatment can effectively reduce the difference in oxidation behavior between dendritic region and interdendritic region. However, due to the inability to form a continuous Al 2 O 3 layer, the oxidation resistance of heat-treated specimens degrades. • The elements distribution will affect the oxidation behavior of superalloys. • The Al content of the region will affect the morphology of the internal Al 2 O 3 layer. • Heat treatment can reduce the oxidation difference between dendritic region and interdendritic region. • After heat treatment, the alloy is more prone to large-scale oxide spalling. [ABSTRACT FROM AUTHOR]

Understanding the high-temperature initial oxidation mechanism and its dynamic processes is generally important because a small amount of initial oxidation can induce rapid corrosion and cause catastrophic failure. We reveal the mechanism of initial oxidation in a third-generation Ni-based superalloy by in situ visualizations and investigations of the nano- and atomic-scale dynamic processes from room temperature to 900 °C with a Cs-corrected environmental transmission electron microscope. The initial oxidation starts from the γ/γ′ interface at low temperatures. The high-temperature oxidation process with deficient oxygen prefers oxidation sites at the cross-junctions of the γ/γ′ interfaces. The growth rate of the oxide nanoparticles depends on the oxidation temperatures, with a low rate below 600 °C and a rapid-growth speed at temperatures higher than 700 °C. Mass transfer from the γ′ and γ phases to the γ/γ′ interface, particularly at the cross-junctions of these interfaces, is observed to cause oxide accumulation. This study provides a direct observation of the interphase, interface-junction-initiated outward oxidization including Al and Cr elements. These results shed light on the initial oxidation mechanisms of materials containing a second phase with interphase interfaces and the materials at deficient oxygen conditions as well as those with protection coating layers. [Display omitted] [ABSTRACT FROM AUTHOR]