Microstructural features underpinning the mechanical behavior of powder metallurgy Cr-based alloys

Lim, Bryan; Fancher, Chris M.; Brookins, Jeffrey M.; Nayir, Selda; Poplawsky, Jonathan D.; Boebinger, Matthew G.; Brennan, Marissa C.; Buresh, Steve; Spencer, Michael; Gordon, Brian; Nandwana, Peeyush

doi:10.1016/j.jallcom.2025.179172

Title: Microstructural features underpinning the mechanical behavior of powder metallurgy Cr-based alloys

Journal Article · 11 February 2025 · Journal of Alloys and Compounds

DOI: https://doi.org/10.1016/j.jallcom.2025.179172 · OSTI ID:2515647

^[1];

^[1]; Brennan, Marissa C. ^[2]; Buresh, Steve ^[2]; Spencer, Michael ^[3]; Gordon, Brian ^[3];

^[1]

Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
GE Aerospace, Niskayuna, NY (United States)
Touchstone Research Laboratory, Triadelphia, WV (United States)

Refractory materials such as Cr-based alloys offer the potential of enhanced elevated temperature performance but have been limited by their poor formability. However, powder metallurgy has been shown to be a viable pathway to fabricate these alloys. Nanophase separation sintering (NPSS) in particular has been used in the literature to accelerate the densification of powder metallurgy Cr- and W-based alloys. Here, we explore microstructure evolution during NPSS in a binary Cr₈₅Ni₁₅ alloy consolidated via (i) cold pressing & pressureless sintering and (ii) hot isostatic pressing followed by hot extrusion & hot upsetting, and the role of these different processing routes on resulting material properties. The alloy lacked room temperature tensile ductility regardless of consolidation process, with multi-length scale characterization, including scanning electron microscopy, transmission electron microscopy, atom probe tomography, X-ray diffraction, and uniaxial tensile testing, revealing that brittleness was due to intrinsically poor Cr grain boundary cohesion. Tensile testing conducted at 760 °C showed marked strength reduction for the extruded & upset (94 %) condition compared to the pressed & sintered (18 %). The formation of orthorhombic CrNi₂ intermetallics functioned as precipitate strengtheners and prevented elevated temperature softening in the pressed and sintered condition. The findings offer foundational insights into aiding the future development of Cr-based alloys.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE; USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO); USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities (SUF)

Grant/Contract Number:: AC05-00OR22725; EE0009115

OSTI ID:: 2515647

Journal Information:: Journal of Alloys and Compounds, Journal Name: Journal of Alloys and Compounds Vol. 1020; ISSN 0925-8388

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Title: Microstructural features underpinning the mechanical behavior of powder metallurgy Cr-based alloys

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