Mechanisms of Rhenium on Wettability and Interactions Between Nickel-Base Superalloy Melt and Al2O3-Based Ceramic Material

doi:10.1007/s40195-020-01030-2

Abstract

Abstract:

A systematic study on the wettability and interactions between superalloy melts with various Re contents and Al₂O₃-based ceramic moulds was presented in this paper. It was found that the increase of Re content inhibited the interfacial reactions to some extent. With regard to the 0, 1.5 and 3Re alloys, a double reaction layer containing Al₂O₃ and HfO₂ was formed at the interface, but the thickness of reaction layer decreased with the increase of Re content. However, only Al₂O₃ phase was detected at the interface when the content of Re was 6 wt%, and the interface reaction was the weakest and the thickness of reaction layer was the thinnest. The wetting angle of the alloy/ceramic system increased as the level of Re increased. Moreover, the formation of viscous sand at the interface mainly depended on the change of wetting angle of the system.

Key words: Superalloy melt, Al₂O₃-based ceramic mould, Interactions, Wettability, Rhenium

Yun Zi, Jie Meng, Chaowei Zhang, Yizhou Zhou, Yutian Ding. Mechanisms of Rhenium on Wettability and Interactions Between Nickel-Base Superalloy Melt and Al₂O₃-Based Ceramic Material[J]. Acta Metallurgica Sinica (English Letters), 2020, 33(7): 1021-1030.

Figures/Tables 16

Fig. 1 SEM image (a), 3D image (b) of the surface morphologies of ceramic substrate

Fig. 2 Macroscopic images of wetting angles between different alloy melts and the ceramics

Fig. 3 Variation trend of the wetting angle with various contents of Re

Fig. 4 Morphologies of the four alloy bottoms: a 0Re, b 1.5Re, c 3Re, d 6Re

Table 1 Chemical compositions of the reaction zones in Fig. 4 obtained via EPMA (at.%)

Position	Ni	W	Ta	Al	O	Cr	Co	Mo	Re	Si
1	0.3467	-	-	34.9272	53.3338	0.2329	0.0412	0.0027	0.0056	11.1099
2	1.3726	0.0281	0.0068	43.3893	54.8898	0.0948	0.1976	0.0127	0.0058	0.0026
3	0.8072	0.0066	-	44.1792	54.8130	0.0785	0.1155	-	-	-
4	0.1768	0.0499	0.0088	45.8245	53.9325	-	-	0.0074	-	-
5	56.7870	1.3220	2.2166	14.0153	17.0767	1.8132	5.9278	0.4441	0.3974	-
6	0.8263	0.0201	-	41.1192	57.8826	0.0642	0.0812	-	0.0065	-
7	0.6404	-	-	43.6272	55.6374	0.0437	0.0706	0.0007	-	-
8	1.0203	0.0282	0.0224	42.3081	56.4644	0.0414	0.1151	-	-	-
9	58.6180	0.1800	1.9125	16.4942	14.1468	2.0493	5.0551	1.0114	0.5327	-

Fig. 5 XRD patterns of the four alloy bottoms: a 0Re, b 1.5Re, c 3Re, d 6Re

Fig. 6 Morphologies of longitudinal section of the four alloys: a 0Re, b 1.5Re, c 3Re, d 6Re

Table 2 Chemical compositions of the interfaces in Fig. 6 determined by EDS (at.%)

Position	Al	O	Si	Ni
1	33.92	50.04	16.03	-
2	36.05	58.93	3.40	1.62
3	43.25	55.66	-	1.09
4	44.81	53.72	-	1.47
5	39.44	57.58	-	2.98

Fig. 7 Surface morphologies of ceramic moulds after the interface reactions: a 0Re, b 1.5Re, c 3Re, d 6Re

Table 3 Chemical compositions of the white particles in Fig. 7 obtained by EPMA (at.%)

Position	Ni	W	Ta	Al	O	Cr	Co	Mo	Re	Si	Hf
1	1.2653	-	0.3264	24.1036	57.4582	0.0685	0.0932	0.0100	-	-	16.6748
2	0.2151	-	0.1357	31.9700	52.8284	0.0100	0.0327	-	-	-	14.8081
3	1.0125	0.0021	0.5241	26.8082	55.6472	-	0.0582	0.0096	-	-	15.9381

Fig. 8 XRD patterns of the ceramic surfaces: a 0Re, b 1.5Re, c 3Re, d 6Re

Fig. 9 Si 2p XPS spectrum of the 3Re alloy bottom

Table 4 Binding energies of related phases in literature [23]

Element	Phase	Binding energy (eV)	Literature data
Al	α-Al₂O₃	Al 2p	74.70
Al	Al₂O₃	Al 2p	73.62
O	α-Al₂O₃	O 1s	532.20
O	Al₂O₃	O 1s	531.60
Si	SiO_0.93	Si 2p	101.90

Fig. 10 Al 2p (a) and O 1s (b) XPS spectra of the 3Re alloy bottom

Fig. 11 Schematic diagram of the whole interfacial reaction process

Fig. 12 Schematic diagram of the penetration of the molten alloy into the ceramic

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Mechanisms of Rhenium on Wettability and Interactions Between Nickel-Base Superalloy Melt and Al₂O₃-Based Ceramic Material

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