Publications

Aubert, James H.; Leming, Sarah L.; Susan, D.F.; Wavrik, Richard W.

Abstract not provided.

Susan, D.F.; Crenshaw, Thomas B.; Grant, Richard P.; Kilgo, Alice C.; Wright, Robert D.

The stainless steel alloy 17-4PH contains a martensitic microstructure and second phase delta ({delta}) ferrite. Strengthening of 17-4PH is attributed to Cu-rich precipitates produced during age hardening treatments at 900-1150 F (H900-H1150). For wrought 17-4PH, the effects of heat treatment and microstructure on mechanical properties are well-documented [for example, Ref. 1]. Fewer studies are available on cast 17-4PH, although it has been a popular casting alloy for high strength applications where moderate corrosion resistance is needed. Microstructural features and defects particular to castings may have adverse effects on properties, especially when the alloy is heat treated to high strength. The objective of this work was to outline the effects of microstructural features specific to castings, such as shrinkage/solidification porosity, on the mechanical behavior of investment cast 17-4PH. Besides heat treatment effects, the results of metallography and SEM studies showed that the largest effect on mechanical properties is from shrinkage/solidification porosity. Figure 1a shows stress-strain curves obtained from samples machined from castings in the H925 condition. The strength levels were fairly similar but the ductility varied significantly. Figure 1b shows an example of porosity on a fracture surface from a room-temperature, quasi-static tensile test. The rounded features represent the surfaces of dendrites which did not fuse or only partially fused together during solidification. Some evidence of local areas of fracture is found on some dendrite surfaces. The shrinkage pores are due to inadequate backfilling of liquid metal and simultaneous solidification shrinkage during casting. A summary of percent elongation results is displayed in Figure 2a. It was found that higher amounts of porosity generally result in lower ductility. Note that the porosity content was measured on the fracture surfaces. The results are qualitatively similar to those found by Gokhale et al. and Surappa et al. in cast A356 Al and by Gokhale et al. for a cast Mg alloys. The quantitative fractography and metallography work by Gokhale et al. illustrated the strong preference for fracture in regions of porosity in cast material. That is, the fracture process is not correlated to the average microstructure in the material but is related to the extremes in microstructure (local regions of high void content). In the present study, image analysis on random cross-sections of several heats indicated an overall porosity content of 0.03%. In contrast, the area % porosity was as high as 16% when measured on fracture surfaces of tensile specimens using stereology techniques. The results confirm that the fracture properties of cast 17-4PH cannot be predicted based on the overall 'average' porosity content in the castings.

Susan, D.F.; Kilgo, Alice C.; Vianco, Paul T.

Abstract not provided.

Proposed for publication in Materials Characterization.

Susan, D.F.; Susan, D.F.; Puskar, J.D.; Robino, Charles V.

Abstract not provided.

Oxidation of Metals

Susan, D.F.; Marder, A.R.

The oxidation of nickel-matrix/aluminum-particle composite coatings was studied using thermogravimetric (TG) analysis in air at 800°C for up to 100 hr. Long-term oxidation behavior was investigated with furnace exposures up to 2000 hr. The coatings were applied to nickel substrates by the composite electrodeposition technique and vacuum heat treated for 3-hr at 825°C prior to oxidation testing. The heat-treated coatings contained a two-phase γ(Ni) + γ′(Ni3Al) microstructure and the overall coating composition was approximately 7 wt.% Al. Also examined were uncoated nickel substrates and bulk Ni-Al alloys containing 6.2, 9.0, and 14 wt.% Al. For all samples, mass-gain kinetics were obtained from thermogravimetric (TG) experiments and furnace exposures and the composition and morphology of the oxidation products were examined using optical microscopy, scanning-electron microscopy (SEM), electron-probe microanalysis (EPMA), and X-ray diffraction (XRD). An outer NiO layer and an inner γ-Al2O3 layer formed on the composite-coating surface. The addition of a small amount of Si (about 1-2 at.%) was found to have little effect on Ni-Al composite-coating oxidation behavior. The Ni-Al coatings behave similarly to bulk γ + γ′(Ni3Al) or single-phase γ′(Ni3Al). In addition, at lower temperatures, such as 800°C, the coatings benefit from a small grain size that enhances Al diffusion to the surface to form the protective alumina layer. Based on oxidation kinetics and morphology, a critical Al content of about 6 wt.% was found, below which internal oxidation and higher oxidation mass gains were observed.

Oxidation of Metals

Susan, D.F.; Marder, A.R.

The oxidation behavior of nickel-matrix/aluminum-particle composite coatings was studied using thermogravimetric (TG) analysis and long-term furnace exposure in air at 1000°C. The coatings were applied by the composite-electrodeposition technique and vacuum heat treated for 3 hr at 825°C prior to oxidation testing. The heat-treated coatings consisted of a two-phase mixture of γ (Ni) + γ′(Ni3Al). During short-term exposure at 1000°C, a thin α-Al2O3 layer developed below a matrix of spinel NiAl2O4, with θ-Al2O3 needles at the outer oxide surface. After 100 hr of oxidation, remnants of θ-Al2O3 are present with spinel at the surface and an inner layer of θ-Al2O3. After 1000-2000 hr, a relatively thick layer of α-Al2O3 is found below a thin, outer spinel layer. Oxidation kinetics are controlled by the slow growth of the inner Al2O3 layer at short-term and intermediate exposures. At long times, an increase in mass gain is found due to oxidation at the coating-substrate interface and enhanced scale formation possibly in areas of reduced Al content. Ternary Si additions to Ni-Al composite coatings were found to have little effect on oxidation performance. Comparison of coatings with bulk Ni-Al alloys showed that low Al γ-alloys exhibit a healing Al2O3 layer after transient Ni-rich oxide growth. Higher Al alloys display Al2O3-controlled kinetics with low mass gain during TG analysis.

Acta Materialia

Susan, D.F.; Marder, A.R.

The interdiffusion of Ni matrix/Al particle composite coatings and nickel substrates was studied using electron probe microanalysis (EPMA) and a one-dimensional diffusion model. The initial coating microstructure was a two-phase mixture of γ(Ni) and γ′(Ni3Al). The coating/substrate assemblies were aged at 800 to 1100°C for times up to 2000 h. It was found that aluminum losses to the substrate are significant at 1000°C and above. The experimental results for the diffusion of Al into the substrate were compared with model predictions based on a diffusion equation for a finite layer on an infinite substrate. Using combined experimental and model results, the effects of temperature and coating thickness were determined and a rationale was developed for coating lifetime prediction.

Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science

Susan, D.F.; Misiolek, W.Z.; Marder, A.R.

Electrodeposited metal matrix/metal particle composite (EMMC) coatings were produced with a nickel matrix and aluminum particles. By optimizing the process parameters, coatings were deposited with 20 vol pct aluminum particles. Coating morphology and composition were characterized using light optical microscopy (LOM), scanning electron microscopy (SEM), and electron probe microanalysis (EPMA). Differential thermal analysis (DTA) was employed to study reactive phase formation. The effect of heat treatment on coating phase formation was studied in the temperature range 415 °C to 1000 °C. Long-time exposure at low temperature results in the formation of several intermetallic phases at the Ni matrix/Al particle interfaces and concentrically around the original Al particles. Upon heating to the 500 °C to 600 °C range, the aluminum particles react with the nickel matrix to form NiAl islands within the Ni matrix. When exposed to higher temperatures (600 °C to 1000 °C), diffusional reaction between NiAl and nickel produces (γ′)Ni3Al. The final equilibrium microstructure consists of blocks of (γ′)Ni3Al in a γ(Ni) solid solution matrix, with small pores also present. Pore formation is explained based on local density changes during intermetallic phase formation, and microstructural development is discussed with reference to reaction synthesis of bulk nickel aluminides.

Susan, D.F.; Puskar, J.D.; Robino, Charles V.

Abstract not provided.