Effect of applied stress, crystal orientation, and phases on type-II hot corrosion of CMSX-4
Abstract
Gas turbine blades encounter corrosion problems, especially at the bare metal connection between the blades and the rotor. Elevated temperatures, a corrosive environment, and high stress are factors that can reduce blade lifespan. Thus, understanding the relation between corrosion behavior and stress is key to improving the design of turbine blades and their operation. Type-II hot corrosion mechanisms (700 °C in flowing 1000 ppm-SO2 with Na2SO4 on the specimen surface) are representative of this problem, and Meier and Luthra have expertly established the mechanisms of Ni-alloy and Co-alloy systems. However, little research has focused on CMSX-4, which is a Ni-based superalloy single crystal. Moreover, research on the effects of phases (eutectic and γ' size), crystal orientations, and applied stress is lacking. In this research, tests of the early stages of hot corrosion—from 3 minutes to 50 hours of exposure—are performed to develop an understanding of type-II hot corrosion mechanism in CMSX-4.The discovery is that a single Cobalt oxide rich layer is initially formed above NiO in the outward oxidation and turns into spheroids afterward. A unique remnant γ' precipitate structure is observed in the inward oxidation zone and this evidence indicates the preferential corrosion behavior. Sulfur layer above the original surface is one of the causes influencing the overall oxidation thickness by pushing the outward oxidation scale. As-cast CMSX-4 with a wide variety of phases is used to examine the phase effects. With short exposure, coarse γ' phase influences the inward oxidation thickness but the effect becomes less with time. Specimens with different orientations (growth and transverse directions) are used to examine orientation effect. A notched specimen with a wedge was invented to maintain a stress gradient during hot corrosion test. The results suggest that there may be an effect of stress on the overall oxidation thickness.
Degree
Ph.D.
Advisors
Trumble, Purdue University.
Subject Area
Materials science
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