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Title: Ni-base superalloy powder-processed porous layer for gas cooling in extreme environments

Extreme high temperature conditions demand novel solutions for hot gas filters and coolant access architectures, i.e., porous layers on exposed components. These high temperatures, for example in current turbine engines, are at or exceeding current material limits for high temperature oxidation/corrosion, creep resistance, and, even, melting temperature. Thus novel blade designs allowing greater heat removal are required to maintain airfoil temperatures below melting and/ or rapid creep deformation limits. Gas atomized Ni-base superalloy powders were partially sintered into porous layers to allow full-surface, transpirational cooling of the surface of airfoils. Furthermore, these powder-processed porous layers were fully characterized for surface, morphology, cross-sectional microstructure, and mechanical strength characteristics. A sintering model based on pure Ni surface diffusion correlated well with the experimental results and allowed reasonable control over the partial sintering process to obtain a specified level of porosity within the porous layer.
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  1. Ames Lab., Ames, IA (United States)
Publication Date:
OSTI Identifier:
Report Number(s):
Journal ID: ISSN 0032-5899
Grant/Contract Number:
AC02-07CH11358; FWP-2012.03.02; FE-0004000.3.622.053.001
Accepted Manuscript
Journal Name:
Powder Metallurgy
Additional Journal Information:
Journal Volume: 59; Journal Issue: 3; Journal ID: ISSN 0032-5899
Taylor & Francis
Research Org:
Ames Laboratory (AMES), Ames, IA (United States)
Sponsoring Org:
Country of Publication:
United States
36 MATERIALS SCIENCE; gas atomization; powder processing; sintering; controlled porosity; Ni-base superalloy