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Rare Met.

(2022) 41(1):218–225 RARE METALS


https://doi.org/10.1007/s12598-018-1103-1 www.editorialmanager.com/rmet

Mechanism of yttrium in deep desulfurization of NiCoCrAlY alloy


during vacuum induction melting process
Jin-Peng Li, Hua-Rui Zhang* , Ming Gao, Qing-Ling Li, Jie Zhang,
Bo Yang, Hu Zhang

Received: 21 October 2017 / Revised: 12 March 2018 / Accepted: 16 June 2018 / Published online: 24 August 2018
Ó The Nonferrous Metals Society of China and Springer-Verlag GmbH Germany, part of Springer Nature 2018

Abstract In this study, yttrium as desulfurizer on the against high-temperature oxidation and hot corrosion
purification of Ni–20Co–20Cr–10Al–Y alloy during vac- [1–3]. MCrAlY alloys contain Al and Cr at concentrations
uum induction melting (VIM) process using Y2O3 cru- so that continuous scales of Al2O3 and Cr2O3 are formed
cibles was investigated experimentally. It is found that Y on alloys during oxidation [4]. Y is present in the MCrAlY
plays an important role on the desulfurizing of the NiCo- alloys to improve the adherence of Al2O3 scales to these
CrAlY alloy. Without any addition of Y, merely the coatings. The adherence of the protective oxide scale to the
employment of Y2O3 crucibles could effectively reduce S base metal (Ni-based alloys) is crucial to oxidation resis-
content of the alloy melts from 28 9 10-6 to 6 9 10-6– tance of the components with TBCs [5–7].
7 9 10-6. With addition of 0.8 wt% Y in the alloy, the According to previous studies [8, 9], S is one of the most
concentration of S could further reduce 2 9 10-6– harmful impurities in Ni-based superalloys. It usually
3 9 10-6. The primary interactive mechanism between Y segregates to the oxide–alloy interfaces and weakens the
and molten alloy was concluded to be the synthesis reac- interfacial adhesive bonds between the oxide and Ni-based
tion of Ni3Y phase, Y2S3 phases and YAlO3 phase. In the alloys. Moreover, S can interact with Ni-based alloy
desulfurize slags, Y2S3 phases and YAlO3 phase are found. components to form nonmetallic inclusions as sulfides,
No secondary contamination is present in the alloy melts which are stress concentrators and initiate cracking during
after addition of Y. operation [10]. As reported by Sun et al. [11], S has a low
solubility in Ni and easily forms a low melting point
Keywords Yttrium; Desulfurization; Vacuum induction eutectic phase along grain boundaries and interfaces,
melting; Y2O3 crucibles; NiCoCrAlY alloy leading to degrade the mechanical properties of the alloys
at high temperature. As shown by Dong et al. [12], when S
content increased from 15 9 10-6 to 50 9 10-6, the
1 Introduction elongation of the Inconel 718 alloy decreased from 10% to
5%, and when S content increased from 56 9 10-6 to
MCrAlY (M = Ni and/or Co) alloys are widely used as 175 9 10-6, the durable life was reduced by 68%.
overlays or bond coats for thermal barrier coatings (TBCs) Therefore, to achieve high and stable properties of nickel-
to protect gas turbine blades and other hot components based superalloys, the content of S in alloy matrix must be
lower than 0.001 wt%.
In order to remove S from the alloys during melting,
J.-P. Li, H.-R. Zhang*, M. Gao, Q.-L. Li, J. Zhang, H. Zhang
electroslag remelting (ESR) technique is usually applied
School of Materials Science and Engineering, Beihang
University, Beijing 100191, China after the process of vacuum induction melting (VIM) and/
e-mail: huarui@buaa.edu.cn or vacuum arc remelting (VAR) [13–15]. As reported by
Chen et al. [14], the S content of GH4169 alloy could be
H.-R. Zhang, M. Gao, B. Yang, H. Zhang
reduced from 18 9 10-6 to 6 9 10-6 when various mix-
Beijing Key Laboratory for Advanced Functional Material and
Thin Film Technology, Beihang University, Beijing 100191, tures within the slag-making system of 60CaF2–20CaO–
China 20Al2O3 were used during the process of VIM ? ESR.

123
Mechanism of yttrium in deep desulfurization of NiCoCrAlY alloy 219

However, these slagging practices of desulfurization could Table 1 Designated composition of Ni–20Co–20Cr–10Al–Y alloy
adversely affect the lifetime of the oxidic refractory lining with three different additions of Y (wt%)
due to the high oxygen affinity of Ca and Mg [16–18]. Alloys Ni Co Cr Al Y
Furthermore, the efficiency of these practices was compa-
Y00 Bal. 20 20 10 0
rably low because of the long production cycle and the high
energy consumption. In consideration of the aforemen- Y08 Bal. 20 20 10 0.8
tioned disadvantages of the ESR, many researchers [19–22] Y15 Bal. 20 20 10 1.5
attempted to merely choose different slag compositions and
additives to remove S in alloys during VIM process.
In Li et al.’s work [21], the effect of Ce on the desul- 2.2 Experimental process
furization of Ni–Cr alloy was studied during VIM process
using MgO crucibles. The results showed that the addition The alloys were melted in a 100KW ZG125C vacuum
of 0.14 wt% Ce reduced the S content from 32 9 10-6 to induction furnace equipped with high-purity Y2O3 cru-
11 9 10-6. As reported by Sidorov et al. [22], the S con- cibles (99.9%). Before melting, the chamber was evacuated
tent in the ZhS32-VI alloy decreased from 20 9 10-6 to down to vacuum degree of 3.5 9 10-3 Pa and backfilled
5 9 10-6, based on the combined addition of slagging with pure argon (O2 \ 10 9 10-6; N2 \ 50 9 10-6;
materials of 0.3 wt% Ca, Mg and Y during VIM using H2 \ 5910-6; CH4 \ 4910-6) up to 0.05 MPa three
MgO crucibles. However, a crucial negative problem was times to reduce the O content to a minimum level and to
revealed when adding RE into the superalloy melts. Under avoid the evaporation of alloy components. The super-
the high-temperature and long-time condition of melting, heating temperatures of the VIM process were designated
RE and other active elements in the melt seriously reacted to be 1550, 1600 and 1700 °C, respectively. Then the
with the traditional crucible materials, such as MgO, CaO. alloys were poured into a graphite mold with a diameter of
Those products including sulfides deposited on the crucible 70–90 mm and a ceramic filter on the gate, and the pouring
inwalls and might contaminate subsequent melts [23, 24]. temperature was 1550 °C.
Previous work showed that the Y2O3 materials with In order to investigate the possible interactive mecha-
higher chemical stability than traditional crucible materials nism between the addition Y and alloy melts, the samples
had the potential to reduce the alloy–crucible interface of the slags were collected from different locations of the
reaction, which has been successfully used as an ideal remained alloy liquid-solidified on the surface of the filter.
crucible for smelting superalloys containing Al, Ti, Hf, etc. The metallographic specimens for characterization were
[25–27]. The latest works further showed that S content collected from the bottom of the as-cast ingots as well as
could be reduced when VIM of MCrAlY alloys using Y2O3 the samples for chemical analysis.
crucibles and Y was conducive to the purification of the
molten alloys. However, the influence of Y on the deep 2.3 Samples analysis
desulfurization of the alloys during VIM process remains
unclear. In this study, the mechanism of Y2O3 crucibles The content of O in alloy was determined by inert gas
and various amounts of Y addition on the deep desulfur- fusion-infrared absorption method according to GB/T
ization of Ni–20Co–20Cr–10Al–Y alloy using VIM 11261-2006, using LECOONH8366 analyzers with an
method was studied. The interactive mechanisms between accuracy of ± 1910-6. S content was determined by
Y and alloy melt during the process were also discussed. combustion-infrared absorption method according to GB/
T20123-2006, using Plasma1000 analyzers with an accu-
racy of ± 0.5 9 10-6. The prepared samples were fed into
2 Experimental specific crucibles and directly heated to the given tem-
perature. The oxygen and sulfur in the sample were pre-
2.1 Materials cipitated by carbon monoxide (or carbon dioxide) and
sulfur dioxide, guided to the infrared detector for deter-
The designated chemical compositions of Ni–20Co–20Cr– mination. Yttrium was analyzed by dissolving samples and
10Al–Y alloy (wt%) with three different amounts of Y comparing the solutions with known standards. The solu-
addition (marked as Y00, Y08 and Y15) are shown in tions were compared in a plasma flame emission spec-
Table 1. The original contents of S and O in the raw trometer with an accuracy of ± 5910-6. The other major
materials were calculated to be * 28 9 10-6 elements were analyzed, using standard X-ray fluorescence
-6
and * 111 9 10 according to the element ratios of (XRF, SPECTRO XEPOS) techniques. The chemical
alloys and the measured values of S and O in each alloying analysis presented here corresponds to the total content,
elements.

Rare Met. (2022) 41(1):218–225 123


220 J.-P. Li et al.

which includes both the amount of dissolved impurities and is the blocky accumulation region in Y15 alloy (Fig. 2d). It
the impurities present in solid inclusions. illustrates that the aggregation state of Y2S3 and YAlO3 in
Phase analysis was carried out by micro-area X-ray the molten slags is different under different Y additions.
diffraction (XRD, D/MAX-2500). Microstructure of the
specimens was observed by scanning electron microscope 3.3 Microstructure of alloys
(SEM, Nova NanoSEM 450) and transmission electron
microscope (TEM, JEM-2100) equipped with an energy- Figure 3 shows the microstructure and XRD results of the
dispersive spectroscopy (EDS). Ni–20Co–20Cr–10Al–Y as-cast alloy with different Y
additions under different refining temperatures. There are
two different areas in Y00 alloy, the black contrast area and
3 Results and discussion the gray contrast area (Fig. 3a, d, g). XRD results in Fig. 3j
show that there are three phases, i.e., c phase (fcc, struc-
3.1 Analysis of S content tural matrix phase), c0 phase (Ni3Al) and Al14Co3Ni3
phase. For Y08 and Y15 alloys, a new phase with main
Figure 1 shows the effect of Y addition on S content in the composition elements of Ni and Y appears (Fig. 3b, c, e, f,
alloy matrix under different refining temperatures. It can be h, i) and it is identified as Ni3Y by XRD patterns in Fig. 3k,
seen that the use of Y2O3 crucibles in VIM could effec- l. It can be seen that Y can change the distribution of
tively reduce S content of the alloy melts from 28 9 10-6 Al14Co3Ni3 phase and the morphology of Al14Co3Ni3
to 6 9 10-6–7 9 10-6, and it is lower than that in Ref. phase changes from massive or thin rod to ellipsoidal after
[21] (11 9 10-6). S content further decreases to adding Y at 1600 °C (Fig. 3d–f). And the number of Ni3Y
2 9 10-6–3 9 10-6 when Y addition increases from at c/c0 eutectic phase matrix increases with the Y addition
0 wt% to 0.8 wt% and it is lower than that in Ref. [22] increasing.
(5 9 10-6). However, S content does not continue to Figure 4 shows Y-rich phases observed in a TEM
decrease but increases to 5 9 10-6–6 9 10-6 when Y extraction replica from Y08 alloy. TEM results also show
addition increases from 0.8 wt% to 1.5 wt%. that there is a common phase (white area in Fig. 3f) in
alloy Y08. When the addition of Y increases to 0.8 wt%,
3.2 Component analysis of slags the selected area diffraction patterns (SADPs) of [0001]
 zone axis of the phase of a white area (Fig. 4b,
and ½0223
Figure 2 shows the surface morphologies and micro-XRD c) are obtained. It is identified as Ni3Y which has a fcc
results of the molten slags from alloys. It can be seen that structure. Those results also show that it is mainly Ni3Y
Y2S3 phase exists in the white stripe area in the slags of phase and there are multi-phase regions consisting of two
Y00 alloy (Fig. 2a). Those small granular compounds with phases (Fig. 4a), namely Ni3Y phase and Al14Co3Ni3
a sharp triangular or pyramidal shape are also Y2S3 phases phase. TEM observation reveals that the morphology of
and the size is small, only 0.5 lm in Y08 alloy (Fig. 2b). Ni3Y with the grain size of 0.2–0.8 lm is sharp angle sheet
At the same time, YAlO3 phases are the larger inclusions in shape, sheet or bulk shape, and Al14Co3Ni3 is needle-like
the form of granules in the Y08 alloy (Fig. 2c). However, it or tubular shape distributed around Ni3Y. More impor-
tantly, Y2S3 or other S-rich phases are not found in the
grains or grain boundaries.

3.4 Effects on desulfurization

The process of deoxidation and desulfurization of Ni–


20Co–20Cr–10Al–Y alloy can be divided into three stages:
first, the rapid deoxidation and desulfurization under high
temperature, high vacuum and electromagnetic stirring in
the initial stage of melting; second, the stable deoxidation
by Al and desulfurization by Y2O3 crucible in the late stage
of melting; and third, the deep desulfurization by Y in the
stage of refining. By using the Y2O3 crucibles, S content of
alloy melts without Y addition could reduce to 6 9 10-6–
7 9 10-6. Adding 0.8 wt% Y can further reduce the con-
Fig. 1 Variation of S content as a function of refining temperatures tent of trace S to 2 9 10-6–3 9 10-6 in the alloys.
and Y addition

123 Rare Met. (2022) 41(1):218–225


Mechanism of yttrium in deep desulfurization of NiCoCrAlY alloy 221

Fig. 2 SEM images of surface morphologies (a Y00 alloy, b, c Y08 alloy and d Y15 alloy) and micro-XRD patterns of untreated slags at
1600 °C (e Y00 alloy and Y08 alloy; f Y08 and Y15 alloy)

However, when the adding amount increases to 1.5 wt%, molten state is a complex system of multi-phase and multi-
the alloy with 5 9 10-6–6 9 10-6 S is obtained. component; among all the possible compounds, Y2O3,
Since Y2O3 crucible was used to melt Ni–20Co–20Cr– Y2O2S and sulfides of the form YS and Y2S3 possess the
10Al–Y alloy at a high temperature, Y in the crucible may lowest free energy of formation and are the most probable
be diffused into the melted alloy. After refining, the compounds that will form when Y is added to alloys
residual Y of Y00 alloy is 15 9 10-6 (1550 °C), containing S and O [28, 30]. Du et al. [28] and Wilson et al.
36 9 10-6 (1600 °C) and 57 9 10-6 (1700 °C), respec- [29] studied the phase equilibria of Ni–Y–S–O solutions at
tively, as shown in Table 2. 1600 °C and provided the basis for predicting the sequence
The rare earth elements are a strong oxide and sulfide- and type of yttrium equilibrium phases formed in nickel-
forming element due to their low free energies of forma- based solutions. According to their works, the existence
tion. Ni–20Co–20Cr–10Al–Y alloy in high-temperature condition of three rare earth compounds is obtained

Rare Met. (2022) 41(1):218–225 123


222 J.-P. Li et al.

Fig. 3 SEM images (a 1550 °C, Y00; b 1550 °C, Y08; c 1550 °C, Y15; d 1600 °C, Y00; e 1600 °C, Y08; f 1600 °C, Y15; g 1700 °C, Y00;
h 1700 °C, Y08; i 1700 °C, Y15) and micro-XRD patterns of alloy matrix: j Y00 alloy, k Y08 alloy and l Y15 alloy at temperatures of 1550,
1600 and 1700 °C

(Fig. 5) and the compound that will form first will depend Under the experimental conditions, 10 wt% Al was
on the relative O and S concentration present in the alloys. added for alloying and Al is conducive to the depth of
Those points on the two lines indicate the coexistence of deoxidation (O content is very low before adding Y).
the two substances. It can be seen that at high oxygen level According to Table 2, the O-to-S content ratio is smaller
Y2O3 will form first until O decreases to a level at which than 10, so O-to-S content ratio exists in the region where
Y2O2S will form followed by Y2S3. Y2O3 and Y2O2S exist Y2S3 exists (Fig. 5). That is to say, when Y is added, it
in a wide range, and Y2S3 exists in a narrower range. Single reacts with the trace amount of S in the alloys to form
rare earth oxides and rare earth sulfides are less common. Y2S3. Interfacial tension between Y2S3 particles and

123 Rare Met. (2022) 41(1):218–225


Mechanism of yttrium in deep desulfurization of NiCoCrAlY alloy 223

Fig. 4 TEM images of precipitates in Y08 alloy at 1600 °C: a morphology of Ni3Y phase, b SADP of Ni3Y [0001] phase and c SADP of Ni3Y
 phase
½0223

Table 2 Chemical analysis of Y, Al and O residue as a function of addition to alloys


Alloys Y content/wt% Al content/wt% O residue/wt% O/S ratio
Addition Residue Addition Residue

1550 °C
Y00 0 0.0015 10 9.89 0.0013 2.17
Y08 0.8 0.6600 10 9.81 0.0014 7.00
Y15 1.5 1.3500 10 9.78 0.0014 2.80
1600 °C
Y00 0 0.0036 10 9.63 0.0006 0.86
Y08 0.8 0.6400 10 9.59 0.0006 2.00
Y15 1.5 1.2400 10 9.52 0.0005 0.83
1700 °C
Y00 0 0.0057 10 9.76 0.0006 1.00
Y08 0.8 0.6800 10 9.79 0.0006 2.00
Y15 1.5 1.2600 10 9.73 0.0006 1.20

superalloys melt is large, and the density of Y2S3 is low killed special alloys is at low levels, Y added to the alloys
(3.869 gcm-3), which is easy to float. The formation of Y can not only react with Ni and S to form Ni3Y and Y2S3,
compounds in these alloys is substantiated by SEM and but also restore Al2O3 into YAlO3.
XRD analysis of samples observed after casting. As shown in Fig. 7, the residue ratio of Y to Al in alloys
In the process of deep desulfurization, almost all Y2S3 increases from 0.065 to 0.138 (1600 °C), which is con-
go to the surface of alloy liquid in the form of slags, and ducive to promoting the reaction to proceed forward,
Y2S3 or other S-rich phases are not found in the grains or resulting in a large number of YAlO3. Because of the low
grain boundaries. Therefore, when Y2O3 crucibles were hardness and high expansion coefficient of YAlO3, the slag
used to refine alloys with different amounts of Y addition, absorption ability of alumina inclusion is promoted, and
there are no S-rich phases inside the alloys, which will not some sulfides and oxides tend to congregate around YAlO3.
cause secondary pollution to the alloys. The rare earth At this point, these oxides and sulfides are generated during
elements could modify alumina into RE aluminates the first and second stages, not the third stage (deep
[30, 31]. Figure 6 shows the desulfurization process of desulfurization stage). After the first and second stages,
alloy melts with Y refining. When O content of the Al- only 13 9 10-6 O and 6 9 10-6 S remain in Y15 alloy

Rare Met. (2022) 41(1):218–225 123


224 J.-P. Li et al.

smaller Y2S3 phase generated in the third stage, and it


cannot play the role of deep desulfurization.
In general, Y added to the Ni–20Co–20Cr–10Al–Y alloy
is first dissolved in the solid solution. When the amount of
Y addition exceeds the solid solubility of nickel-based
alloys, Y will appear in the form of Y-rich precipitates. Y
reacts with Ni to form Ni3Y which has a remarkable
influence on the driving force of Al14Co3Ni3 phase growth,
and it can change the morphology of Al14Co3Ni3 phase. Y
reacts with S to form Y2S3 and reacts with Al2O3 to form
YAlO3, which go to the surface of the melt in the form of
slags, thus playing an important role in deep
desulfurization.

Fig. 5 Phase field for most probable oxide, oxysulfide and sulfide in
nickel liquid
4 Conclusion

In this study, the effects of deep desulfurization of Y were


studied for Ni–20Co–20Cr–10Al–Y alloy during VIM
process. The corresponding mechanisms were also dis-
cussed. Experimental results show that, by using Y2O3
crucibles, S content of alloy melts without Y addition could
reduce from 28 9 10-6 to 6 9 10-6–7 9 10-6. When
adding 0.8 wt% Y, the S content of alloys could further
reduce 2 9 10-6–3 9 10-6. When the adding amount
increases to 1.5 wt%, the S content of the alloy increases to
5 9 10-6–6 9 10-6 S. The primary interactive mechanism
between Y and molten alloy was concluded to be the
Fig. 6 Schematic diagram of desulfurization process of alloy melts synthesis reaction of Ni3Y, Y2S3 and YAlO3 phase. Ni3Y
with Y refining phases have a remarkable influence on the driving force of
Al14Co3Ni3 phase growth. Y2S3 and YAlO3 phases play an
important role in deep desulfurization.

Acknowledgements This study was financially supported by the


National Science & Technology Pillar Program of China (No.
2013BAB11B04) and the National Natural Science Foundation of
China (No. 51404017). Furthermore, the authors wish to express their
appreciation to the State Key Laboratory of Refractories and Metal-
lurgy, Wuhan University of Science and Technology.

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