Developing Core-Shell Nano-Structures in FeCrAl-ODS Ferritic Alloys with the Co-Addition of Ni and Zr

doi:10.1007/s40195-023-01621-9

Abstract

Abstract:

A new Ni + Zr co-alloyed FeCrAl-ODS (oxide-dispersion-strengthened) ferritic alloy was fabricated by ball-milling and hot-isostatic-pressing. Using electron microscopy and atom probe tomography, the dispersive formation of high density core-shelled nano-particles of various sizes was confirmed with a common B2-NiAl shell. Among which, median-sized nano-particles (20-50 nm) typically have an Y₄Al₂O₉ nano-core of < ~ 20 nm, ultra-fine nano-particles (< ~ 20) nm have an Y₄Zr₃O₁₂ nano-core of < ~ 10 nm, and larger-sized nano-particles (50-100 nm) incorporate an ultra-fine Y₄Al₂O₉ nano-core and a few ultra-fine Y₄Zr₃O₁₂ nano-oxides. All these nano-phases were highly coherent with the ferritic matrix. No large Y-Al-O nano-oxides were formed. The total number density of ultra-fine nano-particles was estimated as ~ 2 × 10²³ m⁻³ with a mean size of 6.3 nm only, and accordingly, the new alloy achieved an excellent combination of strength and ductility at high temperatures.

Key words: FeCrAl, Oxide-dispersion-strengthened (ODS) alloy, Mechanical alloying, Nano-oxides, Core-shell

Wenquan Ding, Jieli Ma, Yong Jiang, Yiren Wang, Huiqun Liu. Developing Core-Shell Nano-Structures in FeCrAl-ODS Ferritic Alloys with the Co-Addition of Ni and Zr[J]. Acta Metallurgica Sinica (English Letters), 2024, 37(2): 364-372.

Figures/Tables 8

Table 1 Real chemical compositions of the new FeCrAl-ODS alloy

	Cr	Al	Ni	Zr	W	Y	O	C
wt%	14.8	2.40	5.91	0.74	1.99	0.25	0.28	0.06
at.%	15.5	4.84	5.48	0.44	0.59	0.15	0.95	0.28

Fig. 1 a HAADF-STEM image of the annealed Ni + Zr co-alloyed FeCrAl-ODS alloy and the EDS line scan profile across the grain boundary as indicated by a green line. b Bright-field TEM image with a higher magnification of the selected area in the red box in a. c Statistical size distribution of the ultra-fine nano-precipitates inside the selected area

Fig. 2 a Bright-field TEM image of dislocation walls and nano-precipitates in the annealed alloy sample. b FFT diffractogram showing a high degree of coherency between B2-NiAl nano-phase and the ferritic matrix. c Dark-field TEM image showing the bimodal size distribution of B2-NiAl nano-phases

Fig. 3 a High-magnification HAADF-STEM image and EDS element mapping of the nano-core inside a typical lager (Ni, Al)-rich shell. b FFT analysis suggesting that the nano-core is an Y4Al2O9 nano-phase, with highly coherency with the B2-NiAl shell and the ferritic matrix as well

Fig. 4 a 3D APT characterization showing that most of low nanometer NiAl-rich nano-particles contain an ultra-fine Y-Zr-O nano-core of ~ 10 nm in diameter. b HAADF-STEM image and EDS element mapping of a Y-Zr-O nano-core wrapped with an incomplete (Ni, Al)-rich shell. c FFT analysis suggesting that the nano-core is a highly coherent Y4Zr3O12 nano-phase

Fig. 5 Uniaxial tensile stress-strain curves of the new FeCrAl-ODS alloy at different temperatures

Table 2 Mechanical properties of the annealed new ODS alloy

Temperature (℃)	YS (MPa)	UTS (MPa)	EL (%)
25	1095 ± 72	1280 ± 20	14.2 ± 0.1
600	497 ± 43	541.5 ± 35	27.9 ± 2.5
700	280 ± 23	318 ± 6	15.5 ± 0.2
800	207 ± 13	230.5 ± 7	13.9 ± 0.8

Fig. 6 YS versus EL data of the new FeCrAl-ODS alloy in comparison with a variety of FeCrAl-ODS alloys in literature, including PM2000 [32,33,34], MA956 [32,33,34], 16Cr3Al [35], and 106YZ alloys [36] (HIP: hot-isostatic-pressing; HE: hot-extrusion; R: rolling; A: annealing)

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