High-Entropy Alloys

Breakthrough Materials for Aero Engine Applications?

By Daniel Svensson, Gothenburg, 13/2 2015

Presentation Outline
1.
2.
3.
4.
5.
6.

Introduction
High-Entropy Alloys
Aero Engine Materials
Bridging the Gap
Suggested Systems
Summary
2

Introduction
GKN Aerospace Engine Systems in
Trollhttan manufactures engine
parts
3
Current superalloys (> 8 g/cm )
High-entropy alloys are potential
candidate materials
3

Introduction
High-entropy alloys is a new type of metallic
materials
Exciting properties
Good strength
Retain strength at elevated temperatures

Introduction
Review high-entropy alloys
Review state-of-the-art aero
engine materials
Identify problems left to solve
Suggest potential highentropy alloy systems
5

Presentation Outline
1.
2.
3.
4.
5.
6.

Introduction
High-Entropy Alloys
Aero Engine Materials
Bridging the Gap
Suggested Systems
Summary
6

High-Entropy Alloys
1.
2.
3.
4.

Definition
Four core effects
Typical properties
Processing routes
7

Definition
Conventional (low- and medium-entropy) alloys
1-3 principal components with 1 or more minor
components
Steels, aluminium alloys...

High-entropy alloys
5-13 principal components
(Not the only definition, they can also be defined
according to their configurational entropy)
AlCoCrFeNi, AlMo0.5NbTa0.5TiZr...

Four Core Effects

1. High mixing entropy effect
Gibbs free energy
High configurational entropy can suppress ordered phases
Especially at higher temperatures

[High-Entropy Alloys - Murty B.S., Yeh J.W., Ranganathan S.]

Four Core Effects

[Sluggish diffusion in CoCrFeMnNi highentropy alloys]

2. Sluggish diffusion effect

Fluctuating potential energy
due to many different
elements
Much coordination of
elements needed
Good elevated temperature properties
10

Four Core Effects

3. Lattice distortion effect
Hinder dislocation movement
solid solution strengthening
Scatter propagating electrons and
phonons
lowered electric and
thermal conductivity

[Solid-Solution Phase Formation Rules for Multi-component Alloys]

Four Core Effects

[High-Entropy Alloys - Murty B.S., Yeh J.W., Ranganathan S.]

4. Cocktail effect
Properties of HEAs not
average of those of
constituent elements
Interaction between
constituing elements
and lattice distortion will
affect properties

AlxCoCrCuFeNi

12

Interesting Properties
Most properties researched has been for
some derivations of the Al-Co-Cr-Cu-Fe-Ni
system
Some research on refractory systems
(Often melted and cast)
13

Strength
The Al-Co-Cr-Cu-Fe-Ni system
Phase constitution varies with Al
content
Strength dependent on the structure
Retain strength at elevated
temperature, especially fcc type alloys
Additional alloying elements (Ti,Mo,Mn,
Nb,Si) also affect the phase
composition

BCC
FCC + BCC

FCC

[Nanostructured High-Entropy Alloys with

Multiple Principal Elements: Novel Alloy
Design Concepts and Outcomes]

14

Strength
Refractory alloys

[Mechanical properties of NbMoTaW and

VNbMoTaW refractory high entropy alloys]

Mostly BCC type, some with

ordered phases
Good elevated temperature
strength
Mostly brittle, though some
systems exhibit good compressive
ductility
Also some Al containing systems
with relativley low densities
15

Fatigue
Limited research
One FCC type system

[Fatigue behavior of Al0.5CoCrCuFeNi high

entropy alloys]

Al0.5CoCrCuFeNi

One BCC type system

Al7.5Cr22.5Fe35Mn20Ni15

Promising results, FCC type

slightly better than BCC
Scattered results, attributed
to microstructural defects
16

Wear
Mainly Al-Co-Cr-Cu-Fe-Ni
system
Not linear with hardness
as opposed to for ferrous
alloys
Type of wear dependent
on constituents (and
crystal structure)

[Mechanical performance of the AlxCoCrCuFeNi highentropy alloy systemwith multiprincipal elements]

17

Oxidation
[Microstructure and wear behavior of AlxCo1.
5CrFeNi1.5Tiy high-entropy alloys]

Not much research

Al +
(Cr +)
Fe AlxCo1.5CrFeNi1.5Tiy
18

Corrosion
Varying corrosion properties, in both H2SO4 and NaCl

[Alloying and Processing Effects on the Aqueous Corrosion Behavior of High-Entropy Alloys]

19

Thermal Properties
AlxCoCrFeNi

Thermal conductivity lower than

in pure metals
Lattice distortion effect
Precipitates
Nanograins
Thermal conductivity increase
with temperature
Lattice distortion
Increase in lattice size

[Microstructure, thermophysical and electrical

properties in AlxCoCrFeNi (0x2) high-entropy
alloys]

20

Processing
Casting
Most common processing
route
Vacuum arc melting or
vacuum induction melting
Copper mold casting
Microstructure depends on
cooling-rate, heattreatments, forging

[High-Entropy Alloys - Murty B.S., Yeh J.W.,

Ranganathan S.]

21

High-Entropy Alloys
Powder metallurgy
More homogeneous
Good when having a wide
range of evaporation
temperatures

http://what-when-how.
com/materialsparts-and-

22

Processing
Thin films/coatings

From vapor state: magnetron

sputtering or plasma nitriding
From liquid state: tungsten inert
gas/gas tungsten arc welding or
laser cladding

Additive manufacturing

FeCoCrNi from selective laser

melting
Better tensile properties than ascast alloys, attributed to the fine
microstructure

http://www.laserstoday.com/2011/05/highperformance-laser-cladding/#more-1035

23

Presentation Outline
1.
2.
3.
4.
5.
6.

Introduction
High-Entropy Alloys
Aero Engine Materials
Bridging the Gap
Suggested Systems
Summary
24

The Aero Engine

1.
2.
3.
4.

Suck
Squeeze
Bang
Blow
http://en.wikipedia.org/wiki/File:Jet_engine.svg

25

Aero Engine Materials

Todays aero engines made
mostly out of four types of
alloys

Aluminium alloys
Steels
Titanium alloys
Nickel alloys (superalloys)

Other exciting new materials

Ceramics
Composites
Intermetallics

[Manufacturing Technology for

Aerospace Structural Materials] 26

Aluminium Alloys and Steels

Aluminium alloys
+ Light-weight (Al density 2.7 g/cm3)
Low temperatures
Low stiffness

Steels
+ Cheap
+ Higher stiffness
Not to high temperatures
27

Titanium Alloys
+
+
+

High strength to weight ratio

Good fatigue strength
Good corrosion resistance
o
Not higher temperatures than ~550 C

28

Nickel Alloys (Superalloys)

+ Able to withstand higher
temperatures than Ti alloys
+ High strength
+ Good fatigue and creep
resistance
+ Good corrosion and
oxidation resistance
High density

[Application of alloy 718 in GE aircraft engines:

past, present and next ve years, Superalloys 718,
625, 706 and various derivatives]
29

Coatings
Diffusion coatings (CoAl, NiAl...)
Overlay coatings (MCrAlY, WCCo...)
Thermal barrier coatings (Y2O3stabilized ZrO2)

[Tbc experience on ge aircraft engines]

30

Other Exciting New Materials

Ceramics (SiC,Al2O3...)
Composites (CMC,MMC)
Intermetallics (NiAl,TiAl...)

31

Density Comparison
High-entropy alloys

Conventional alloys

AlCoCrCuFeNi

7.1* g/cm3

Ti-6Al-4V

4.43 g/cm3

AlCoCrFeNi

6.7* g/cm3

Inconel 718

8.19 g/cm3

AlMo0.5NbTa0.5TiZr

7.4 g/cm3

Haynes 230

8.97 g/cm3

VNbMoTaW

12.36 g/cm3

Waspaloy

8.20 g/cm3

Calculated using rule-of-mixtures with room temperature data

32

Specific Parts
Lower densities than superalloys
Elevated temperature strength

Hot structural components

Turbine Exhaust Case, Mid Turbine Frame, Exhaust
Nozzle and Cone
33

Turbine Exhaust Case

Situated downstream of the
final turbine
Support the low pressure rotor
Mount engine to aircraft body
Remove angular component of
outgoing flow
Exposed to high temperatures
Inconel 718
[Weld sequence optimization:The use of surrogate models
34
for solving sequential combinatorial problems]

Turbine Exhaust Case

Separation of functionalities
Load Carrying Structure

Limited by LCF, strength, stiffness,

creep/thermo mechanical fatigue and
oxidation
Today Inconel 718

Heat Shielding Fairing

Limited by temperature capability,

formability and oxidation
Working temperature 670oC, peak
temperatures of 760oC
Solution hardened alloy

35

Mid Turbine Frame

Situated in between high pressure

and low pressure turbines
Houses the mid turbine bearing,
supporting low and high pressure
rotors
Similar demands as on the TEC, with
a similar separation of functionalities
Load carrying structure in Inconel
718
Heat shielding fairings in Mar-M247 or Mar-M-509
36

Exhaust Nozzle and Cone

Integrate with TEC to
avoid interfaces
Limited by creep,
temperature capability,
surface stability and
weight
Today often titanium
alloys
Research into CMCs
Boeing

37

Presentation Outline
1.
2.
3.
4.
5.
6.

Introduction
High-Entropy Alloys
Aero Engine Materials
Bridging the Gap
Suggested Systems
Summary
38

Bridging the Gap

Fatigue and creep
Little fatigue research, only two systems
Only HCF, not LCF
No creep research
Good creep resistance can be expected from the sluggish
diffusion and lattice distortion core effects
Conventionally creep resistance is increased by
coarsening the grains

39

Bridging the Gap

Oxidation
Little research
Al and Cr conventionally gives good resistance by forming
protective layers

Property and alloy optimization

Balancing properties against each other (e.g. strength
and ductility)
Be aware of eventual problems with the used elements
(expensive, rare, hazardous etc.)

40

Bridging the Gap

Thermal stability

http://forthillhs.com/Students/Student%
20subject%20wepages/Welding/index.html

Not well researched

Many alloys have been in a metastable
state
Alloys will be exposed to high
temperatures for extended periods of
time

Manufacturability

Materials must be formable and

possible to join with other materials
Property scattering from defects needs
to be removed/minimized

41

Presentation Outline
1.
2.
3.
4.
5.
6.

Introduction
High-Entropy Alloys
Aero Engine Materials
Bridging the Gap
Suggested Systems
Summary
42

Suggested Systems
Load Carrying Structure
Al-Co-Cr-Fe-Ni-Mo
Heat Shielding Fairing
Al-Co-Cr-Fe-Ni
Exhaust Nozzle and Cone
AlNbTiV
43

Presentation Outline
1.
2.
3.
4.
5.
6.

Introduction
High-Entropy Alloys
Aero Engine Materials
Bridging the Gap
Suggested Systems
Summary
44

Summary
High-entropy alloys: new exciting material
Four core effects of high-entropy alloys

High mixing entropy

Sluggish diffusion
Lattice distortion
Cocktail effect

45

Summary
Potential for low density metallic alloys with
good elevated temperature properties
Candidates for structural components in the
hotter parts of aero engines
Many problems left to solve

46

Acknowledgements
Chalmers
Sheng Guo

GKN
Magnus Hrnqvist
Bengt Pettersson
Anders Hellgren

47