DTIC ADA283596: Proceedings from the Conference on Critical Issues in the Development of High Temperature Structural Materials Held in Kona, Hawaii on March 7-14, 1993,

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CRITICAL ISSUES
in the
DEVELOPMENT
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HIGH TEMPERATURE
STRUCTURAL MATERIALS
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CRITICAL ISSUES
in the
DEVELOPMENT
of
HIGH TEMPERATURE
STRUCTURAL MATERIALS
Proceedings from the Conference on Critical Issues
in the Development of High Temperature Structural Materials
held in Kona, Hawaii
March 7-14, 1993
EDITED BY
N.S. Stoloff, D.J. Duquette and A.F. Giamnei
APublication of
MS
t
W~nerals -Metas -Matedals
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FOREWORD
This Engineering Foundation Conference was devoted to discussion of the current status
of research and development of superalloys, refractory metals, intermetallic compounds,
ceramics and composites based upon ceramics or intermetallics. The Conference, held in
Kona, Hawaii, March 7-14,1993, was unique in that workers in these diverse fields rarely
converse in a single forum. Coverage of these materials ranged from basic science through
pcesing and mechaicalpropre as well asdiscussion ofcurrent applications (superalloys
and refractory metals) and future applications (principally composites and intermetallics).
In addition, the importance of reducing costs of development of new materials was cited in
the Keynote address of Dr. Ben Wilcox of the recently renamedAdvanced Research Projects
Agency.
The attendees heard that nickel-base superalioys continue to be improved in strength and
in permissible maximum operating temperatures, which now are in excess of 1120r C. New
single crystal alloys containing up to 6% Re promise to raise this temperature still higher,
providing a still more difficult target for designers of new competitive materials such as
ceramic composites. Refractory metals and alloys compete with ceramics for some
applications above 13500 C, but to date intermetallics provide the promise of lower density
and higher thermal conductivity than superalloys or refractory metals at temperatures of
1000-1100P C. Moreover, if MoSi2 can be successfully reinforced so as to simultaneously
improve both toughness and creep resistance, such composites could provide useful
strength and oxidation resistance to at least 15000 C.
It was reported that ultrafine microstructures provide some toughening in MoSi2
composites, and that whiskers or fibers are better than particulates as reinforcements.
Clearly, lack of low temperature ductility and toughness are the principal obstacles to
applications of intermetallics. Creep rupture, fatigue and thermal properties of NiAI already
match or exceed those of current superalloys, but designers appear to be unwilling to
consider new materials with toughness much less than the 50-80 MPadm exhibited by
superalloys at room temperature. However, it was pointed out that designers are not
providing alloy developers with realistic minimum values of toughness that are required for
turbine applications. It was suggested also that perhaps a fairer estimate of needed toughness
might correspond to superalloy values at 7600 C, near the well-known ductility minimum
in superalloys. Another point in favor of NiAl is the finding that the toughness can be
increased to the order of 15MPailm by rapidly cooling from elevated temperatures to avoid
segregation of interstitial impurities and subsequent strain aging, or by purification to
eliminate the interstitials. However, most intermetallics are very sensitive to composition
and, in addition, show marked sensitivity to moisture or hydrogen.
Ceramics and ceramic-matrix composites also have demonstrated improved toughness
in recent years, although there was some dispute about the advisability of designing ceramic
composites with pre- existing cracks. Also, concern was expressed about porosity and the
presence of glassy phases of grain boundaries in powder processed ceramics, since both
factors reduce mechanical properties. Another aspect of ceramic processing that offers the
chance of matching ceramic and metal components was a discussion of functionally
gradient materials (FGM). These can be made by four different processes and allow a
v
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,(cid:127) ,-, (cid:127) (cid:127) II
continuous range of properties frompure metallic to pure ceramic across a single component.
However, the principal problems with all structural ceramics remained inadequate tensile
strength and highly variable strength values.
The need was clearly identified to accelerate the time from conception of new materials
toimpemntaion. This would reduce costs and allow for more rapid iteration.
Management philosophy does not usually have the patience to sustain a ten to twenty year
developmentprogram.An appwoach to the problem of rapid implemtatio is the partrnerhip
or consortium. This circumvents the possibility of an individual or institution working alone
without the nurtring interactions of other companies, universities or government agencies.
By having more input and allowing for more outlets of technology, the pace of progress is
sure to quicken. In addition, the technology has advanced to such a high level in situations
like gas turbine engines, that future advances will very likely call upon interdisciplinary
skills. A new funding paradigm of in-kind funds by participants at least stretches scarce
funds and shows management commitment. From the point of view of industry, this
represents powerfu leveraging and explains the great start-up success of the CRADA (Co-
operative Research and Development Agreement) Program format. These agreements are
for the purpose of fostering joint research efforts between national laboratories and
industrial firms.
The Conference was noteworthy in several respects:
"•d iversity of materials covered
"*r ange of physical and mechanical properties discussed
"•i nclusion of processing and environmental issues
"*e xtensive discussion after each paper and in the panel period on issues
ranging from basic scientific principles to economic considerations.
"*o penness of participants in discussing problems with, as well as,
advantages of, each class of material.
The organizers, who included M. Nazmy, M. Yamaguchi and S. Suresh, are grateful to the
Engineering Foundation for providing seed money to partially defray travel costs of
Conferees. In addition, we acknowledge with thanks the financial support of the Army
Research Office -Durham, Office of Naval Research; Center for Materials Science of Los
Alamos National Laboratory and United Technologies Research Center. Finally, we are
grateful to Mr. Jack Donaldson of the Engineering Foundation for handling all of the local
arrangements in a highly capable manner.
N.S. Stoloff
DJ. Duquette
A.F Giamei
Conference Co-Chairmen
June 14, 1993
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TABLE OF CONTENTS
High Temperature Materials: Processing and Application .................................. I
BA. Wilcox and MA. Rigdon
SESSION I
Alloy Design I
(Theory)
Phase Stability and Alloy Design in High Temperature Intermetallics ................... 15
J.H. Perepezko
Critical Issues in the Computational Materials Science for Structural Materials.......29
MRI.Yoo andC .L. Fu
Alloy Design for Hligh Temperature, Low Density Composite Materials ................ 43
G.l. Reynolds and J.H. Norman
Advanced Hfigh-Temperature Alloys by Design Using
Rapid Solidification Processing............................................................. 57
J.E. Flinn and TYF. Kelly
SESSION HI
Alloy Design H
(Applications-Alloy Development)
Single Crystal Based Microstructure Design of Metal Matrix Composites
for High Temperature Applications ......................................................... 71
R. Rqj
Ni-Based Superalloy Developments ........................................................ 87
G.L. Erickson
SESSION III
Advanced Processing
Advanced Materials Processing............................................................ 109
A.F. Giamne
synthesis and Property Attainment in Ceramiic Matrix Composites..................... 119
WB. Hunlg
The Effect of Processing on the Microstructure and Properties
of Advanced Materials...................................................................... 137
G.E. Fuchs
The Application of Combustion Synthesis in the Production of Titanium-Based
Ceramic and Ceramic-Metal Composites.................................................. 151
Hi. Feng, K.R. HuNer and JJ.M oore
Improvement of Rodtn-Tenperature Ductility of Intermetallic Compounds
by Unidirectional Solidification............................................................ 161
T. Hirano
vii
____ in,
SESSION IV
Strengthening/Toughening Mechanisms I
(Metals and Intenn etaW cs)
Strengthening and Ductilization of Two Phase TWA Alloys in Lamellar
Form Ternary Alloying Additions ......................1.7.3..................
M. Yamaguchi and II. Inud
Strengthening and Toughening in Refr-actory Metal Alloys ...........1.8.9.........
J. Wodrworth, J. Wittenauer and T.G. Nieh
Precipitation in High Temperature AlumiAnides .................2.0.3.............
Al. N~emio&,
Fracture Toughness of Gamma Base Titanium Aluminides
with Ternary Additions at Room and Elevated Temperatures............................ 217
R. Gnananmoorthy, Y. &futah, N. Masahashi and M. Mizuhara
Ductility of NiýAl Doped with Substitutional Elements ................................. 227
S. Hanada,A . Chiba, HZ. Guo and S. Watanabe
SESSION V
Strengthening/Toughening Mechanisms II
(Ceramicsa nd Composites)
CeramiAc Matrix Composites: Challenges and Opportunities ............................ 239
A.G. Evans, i.-A. Domergue and E. Vaggagini
Plastic Anisotropy in MoSi2 Single Crystals ............................................. 279
T.E. Mitchell and SA. Maloy
Microstructural Effects on Creep Strengthening of MoSi½ Matrix Composites .......291
A X. Ghosh and A. Basu
Fundamental Research on Functionally Gradient Materials (FGM) for Relaxation of
Thermal Stress .............................................................................. 303
1.S hiota
SESSION VI
Creep Resistance
Critical Aspects in the Development of Creep Resistant
Superalloys, & Intermetallics............................................................... 321
M. Nazmny
Creep and Damage Process in Multi-Phase Ceramic Materials.......................... 333
D.S. Wilkinson
Designing for Improved High Temperature Strength, Creep, Oxydation,
and Fatigue Resistance in S3N 4 .. . . . . ..............................................349
G. Thomas
viii
SESSION VII
I
Fatigue Resistance
Fatigue of Superalloys and Intermietallics .367................................. 6
N.S. Stoloff
Creep Fracture and Creep-Fatigue Fracture in Ceramics
and Ceramic Composites ................................................................... 385
S. Suresh
SESSION VIII
Environmental
Environmental Embrittlement of Ordered Intermetallics
at Ambient Temperatures ................................................................... 399
T. Takasugi
High Temperature Corrosion of Intennetallics, Ceramics,
and Carbon-Carbon Composites ........................................................... 415
G.H. Meier and F.S. Pettit
Environmental Resistance of Intermetallic Compounds and Composite Materials ...4.31
DJ. Duquette
Environmental Effects on Elevated Temperature Subcritical Crack Growth
of SiC/Sit 'Composites...................................................................... 445
C.H. Henager,J r. and R.H. Jones
Hydrogen and Titanium Base Materials................................................... 455
H.G. Nelson
Plasticity Enhancement Mechanisms in Refractory Metals and Intermetallics......... 465
R. Gibala, H. Chang, C.M. Czarnik, K.M. Edwards and A. Misra
SESSION IX
Governmental Programs
Japanese National Project on Intermetailics............................................... 477
T. Maruo and M. Tomita
Advanced Structural Materials and Processes............................................. 491
A.H. Rosenstein
ix
_______ ___________________ -V.6-
T r~~
V_
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HIGH TEMPERATURE MATERIALS:
PROCESSING AND APPLICATION
Ben A. Wilcox* and Michael A. Rigdon**
* Advanced Research Projects Agency
3701 North Fairfax Drive
Arlington, Virginia 22203
N
and
** Institute for Defense Analyses
1801 N. Beauregard Street
Alexandria, Virginia 22311
(9 Abstract
This paper discusses promising new processing technologies for producing improved high
temperature structural materials. In addition issues are outlined which are beyond the normal
technical realm that are required to move promising new materials into an application.
Approaches to address affordability and shorten the time from discovery to application are
described. New efforts to integrate basic and applied research to further reduce development
cycle time and promote dual defense and civilian technology applications are discussed.
(cid:127)cesionF
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Crtical Isues in the Development of High Temperature Structural Materials
Edited by N.S. Stoloff, DJ. Duqueue and A.F. Giamei
The Minerals, Metals & Materials Society, 1993
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