High Temperature

Materials
By – Prathamesh Kulkarni
Contents:

• 1. Introduction to high-temperature materials

• 2. Characteristics of engineering materials at high temperature
• 3. Oxidation
• 4. High-temperature corrosion
• 5. Creep
• 6. Thermal fatigue
• 7. Erosion
• 8. Aging
• 9. Structural changes
• 10. Material damage
• 11. Crack propagation
• 12. Damage mechanics
• 13. Lifetime analysis
 • High-temperature materials are substances that can
withstand elevated temperatures without significant
degradation in their properties.

What are • These are materials that serve above about 540°C. In
High the broad sense, high-temperature materials can be
identified by the following classes of construction
Temperature solids: stainless steel (limited), austenitic super alloys,
Materials? refractory metals, ceramics and ceramic composites,
metal-matrix composites, and graphitic composites.

• Understanding the behavior of materials at high

temperatures is crucial for various engineering
applications, such as aerospace, power generation, and
industrial processes.
Types of High Temperature Materials:
 •Thermal expansion and contraction: Materials expand
and contract at different rates as temperatures change,
leading to dimensional changes and stress development.
Characteristics of
•Strength and ductility variations: Material strength and
Engineering ductility can decrease or increase significantly at high
Materials at High temperatures, affecting their load-bearing capacity.

Temperatures •Phase changes and microstructural alterations: Elevated

temperatures can cause phase transformations and
changes in the material's microstructure, influencing its
mechanical and thermal properties.

•Oxidation and corrosion resistance: Many materials are

prone to oxidation and corrosion at high temperatures,
impacting their performance and lifespan.
Oxidation:
Oxidation is a chemical reaction
between a material and oxygen in the
presence of heat, leading to the
formation of oxides.
It can result in the degradation of
material properties, such as reduced
strength, increased brittleness, and
diminished corrosion resistance.
Strategies to enhance oxidation
resistance include the use of protective
coatings, alloying elements, and surface
treatments.
High-temperature
corrosion:

• High-temperature
corrosion is a
mechanism of corrosion
that takes place when
gas turbines, diesel
engines, furnaces or
other machinery come in
contact with hot gas
containing certain
contaminants.
Continued:
• For high temperature
corrosion to occur it has to
reach a temperature above
400°C. Such high temperatures
emit a vibrant red light and are
rightfully referred to as red
heat. Without the presence of
liquid electrolytes, this type of
corrosion will commonly occur
as a direct result of the
chemical reaction
between metallic materials
and various gaseous atoms.
Material
strength
Vs Temp.

Creep :
• Creep is the time-dependent
deformation of materials under a
constant load and elevated
temperatures:
• Creep is a phenomenon that occurs
when a material undergoes permanent
deformation over time while being
subjected to a constant load at high
temperatures.
• Unlike instantaneous deformation,
which occurs immediately upon applying
a load, creep is a slow and progressive
process that continues as long as the
load and temperature are sustained.
Mechanisms contributing to
creep in high-temperature
materials:
• Diffusion: At high temperatures,
atoms have increased mobility,
allowing them to migrate through
the material's crystal lattice.
Diffusion enables the
redistribution of atoms and leads
to creep deformation.
• Dislocation movement:
Dislocations, which are crystal
defects, can also move more easily
at elevated temperatures. The
motion of dislocations contributes
to creep deformation by
facilitating the material's plastic
flow.
CREEP CURVE :
Creep Temp.
Mechanisms contributing to creep in
high-temperature materials:
• Diffusion: At high temperatures, atoms
have increased mobility, allowing them to
migrate through the material's crystal
lattice. Diffusion enables the redistribution
of atoms and leads to creep deformation.
• Dislocation movement: Dislocations,
which are crystal defects, can also move
more easily at elevated temperatures. The
motion of dislocations contributes to
creep deformation by facilitating the
material's plastic flow.
Types of creep in high-temperature
materials:
• Primary creep: Initially, the creep rate is
relatively high but gradually decreases over
time. This stage is characterized by the gradual
adjustment of the material's microstructure to
the applied load and temperature.
• Secondary creep: During this stage, the creep
rate remains relatively constant, indicating a
steady-state of creep deformation. This stage is
often the longest and most predictable part of
the creep curve.
• Tertiary creep: In this stage, the creep rate
accelerates, leading to eventual failure. Tertiary
creep is associated with the formation and
propagation of cracks and voids, resulting in
material breakdown.
Factors influencing creep in high-temperature materials:
Temperature: Higher temperatures
promote faster diffusion and dislocation
movement, increasing the likelihood of
creep deformation.
Stress level: Higher stress levels can
accelerate creep deformation by
promoting faster dislocation movement
and facilitating plastic flow.
Material composition: The composition of
high-temperature materials, including
alloying elements and impurities, can
significantly impact their resistance to
creep.
• Microstructure: Factors such as grain size,
grain boundaries, and the presence of
second-phase particles can influence the
material's creep resistance.
• Understanding and characterizing creep
behavior in high-temperature materials is
crucial for designing components that will
be exposed to sustained high
temperatures over extended periods.
Engineers consider creep properties,
conduct creep tests, and incorporate
appropriate design measures to ensure
the safe and reliable performance of high-
temperature applications.
 Thermal fatigue
• Thermal fatigue refers to the failure of materials
subjected to cyclic thermal loading.
• Thermal fatigue (TF) is related to structures subjected
to cyclic thermal loadings that are likely to lead to
initiation of cracks, crack propagation and failure.
Thermal fatigue is the gradual deterioration and
eventual cracking of a material by alternate heating and
cooling during which free thermal expansion is partially
or completely constrained.
• It occurs due to differential thermal expansion and
contraction, resulting in stress accumulation and crack
initiation.
• High temperature fatigue is a vast and complex
problem in which many materials are adopted
nowadays, the vast majority falling into the
following three families:
• 1) 9% – 12% Cr, plus Mo, steels in power
generation industry;
• 2) austenitic stainless steels, in power generation
industry;
• 3) Ni-based superalloys, in gas turbines in jet
engine industry.
• With increased temperature, there is a tendency
for more homogeneous band slip, which delays
the onset of fatigue crack initiation. However, in
most cases increasing the temperature reduces
the lifespan of the material. This decreased
fatigue life is directly related to oxidation.
• Techniques to mitigate thermal fatigue include
thermal barrier coatings, optimized component
design, and controlled temperature gradients.
Erosion at High Temperatures

• Erosion is the progressive loss of

material due to the impact of solid
particles, gas streams, or liquid droplets
at high temperatures.
• High-temperature erosion mechanisms
include abrasion, erosion-corrosion, and
erosion-oxidation.
• Methods to prevent erosion in high-
temperature environments involve
material selection, coatings, erosion-
resistant designs, and particle filtration.
 •
Materials can undergo aging and structural changes when
exposed to high temperatures over time.
Aging and •
Aging processes include precipitation, coarsening, and
Structural grain growth, leading to altered material properties.
Structural changes may include phase transformations,
Changes recrystallization, and thermal decomposition.
•
Aging and structural changes can impact mechanical
strength, hardness, and corrosion resistance.
Material damage mechanisms at high temperatures:

Fatigue: High temperatures can accelerate fatigue damage, leading to the

progressive growth of cracks due to cyclic loading. Fatigue at elevated
temperatures is often caused by thermal cycling, mechanical vibrations, or
thermal-mechanical interactions.

Creep: Creep deformation can cause damage in materials by promoting the

growth of internal voids, cavities, and grain boundary sliding. Creep damage
is typically characterized by the development of microcracks and creep
voids.

Stress corrosion cracking: In the presence of a corrosive environment, high

temperatures can increase the susceptibility to stress corrosion cracking.
This mechanism involves the combined action of mechanical stress and
chemical reactions, leading to crack initiation and propagation.
 ▪ Once a crack initiates in a material, high temperatures can accelerate crack
propagation due to several factors:
▪ Enhanced diffusion: High temperatures increase the diffusion of atoms and
species, facilitating crack growth by promoting atomic rearrangement and
the transport of corrosive species to the crack tip.
Crack propagation at ▪ Reduced material strength: Elevated temperatures can reduce the material's
high temperatures: strength and toughness, making it more prone to crack propagation under
applied stress.
▪ Thermal stress effects: Thermal gradients and thermal expansion mismatch
can induce additional stresses at the crack tip, promoting crack growth.
▪ Material degradation: High temperatures can lead to material degradation,
including oxidation, corrosion, and microstructural changes, which can
weaken the material and facilitate crack propagation.
Mitigating material damage and crack propagation:
• Material selection: Choosing high-temperature materials with good resistance to
fatigue, creep, and stress corrosion cracking can help mitigate damage and crack
propagation.
• Design considerations: Designing components with appropriate geometry, stress-relief
features, and fillet radii can reduce stress concentrations and minimize the risk of crack
initiation and propagation.
• Protective measures: Employing coatings, surface treatments, and corrosion-resistant
alloys can enhance the material's resistance to oxidation, corrosion, and environmental
degradation.
• Inspection and maintenance: Regular inspections, non-destructive testing techniques,
and preventive maintenance programs can identify cracks or damage at an early stage,
allowing for timely repairs or replacements.
• Understanding the material damage mechanisms and crack propagation at high
temperatures is crucial for ensuring the reliability and safety of components exposed to
elevated temperatures. By implementing appropriate material selection, design
strategies, and maintenance practices, engineers can mitigate the detrimental effects
of high-temperature environments and extend the service life of critical components.
Lifetime analysis of high-
temperature materials:
• Lifetime analysis, also known as
service life prediction or durability
assessment, involves estimating the
expected lifespan of high-
temperature materials under
specific operating conditions.
• It is crucial for ensuring the safe
and reliable performance of
components in high-temperature
environments, such as gas turbines,
boilers, and exhaust systems.
Factors influencing lifetime analysis:
•Temperature: The operating temperature plays a
significant role in determining the material's
degradation mechanisms, such as oxidation, creep, and
fatigue, which can affect its lifespan.
•Load and stress: The magnitude and nature of applied
loads and stresses, including thermal stresses,
mechanical loads, and cyclic loading, impact the
material's fatigue and creep behavior, directly
influencing its lifetime.
•Environment: The presence of corrosive gases,
chemicals, or molten salts in the environment can
accelerate material degradation, leading to reduced
lifetime. Environmental factors such as humidity, pH,
and gas composition should be considered in the
analysis.
Thank you