Design of an alumina forming coating for Nb-base refractory alloys

Holgate, Collin S.; Frey, Carolina; Endsley, Melina A.; Suzuki, Akane; Levi, Carlos G.; Pollock, Tresa M.

doi:10.1016/j.matdes.2025.113652

Title: Design of an alumina forming coating for Nb-base refractory alloys

Journal Article · 23 January 2025 · Materials & Design

DOI: https://doi.org/10.1016/j.matdes.2025.113652 · OSTI ID:2510949

^[1];

^[1]; Suzuki, Akane ^[2]; Levi, Carlos G. ^[1]; Pollock, Tresa M. ^[1]

University of California, Santa Barbara, CA (United States)
GE Aerospace Research, Niskayuna, NY (United States)

Refractory multi-principal element alloys (RMPEAs) promise to significantly enhance gas turbine engine efficiency, but their poor oxidation performance inhibits their implementation. Alumina-forming bond coat alloys can provide oxidation protection, but discovering suitable chemistries remains a challenge. We employed a design methodology that screens for alumina-formation capability using Al activity and phase constitution predictions from CalPhaD (Thermo-Calc). Alloy down-selection from approximately 7,800 alloys in the Nb-Si-Ti-Al-Hf system was conducted via analysis of calculated thermodynamic properties with number-density topology style maps. This approach is validated by creating and testing the composition Nb₁₂Si₂₃Ti₂₄Al₃₆Hf₅, which forms protective alumina scales up to 1400 °C and resists pesting at 800 °C. Further, the alloy has an average coefficient of thermal expansion of ~10.1 ppm/K, making it well matched to Nb-based refractory alloys. The methodology will be useful for the design of coatings for RMPEAs, enabling their implementation and significant efficiency benefits sooner.

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Research Organization:: GE Vernova Operations, LLC, Niskayuna, NY (United States)

Sponsoring Organization:: National Science Foundation (NSF); USDOE Advanced Research Projects Agency - Energy (ARPA-E)

Grant/Contract Number:: AR0001420

OSTI ID:: 2510949

Journal Information:: Materials & Design, Journal Name: Materials & Design Vol. 251; ISSN 0264-1275

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Title: Design of an alumina forming coating for Nb-base refractory alloys

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