RARE METALS

Vol. 30, Spec. Issue, Mar 2011, p. 422

DOI: 10.1007/s12598-011-0317-2

Research status and progress of NiAl based alloys as high temperature

structural materials

WANG Jingxina, QIAN Jiuhonga, ZHANG Xuanjia and WANG Yueqib

a
Information Research Institute of Science and Technology, General Research Institute for Non-Ferrous Metals, Beijing 100088, China
b
Ningbo Branch of China Academy of Ordnance Science, Ningbo 315103, China
Received 29 September 2010; received in revised form 29 December 2010; accepted 10 January 2011
© The Nonferrous Metals Society of China and Springer-Verlag Berlin Heidelberg 2011

Abstract

With the development of science and technology, comprehensive performance of high temperature structural materials were demanded ur-
gently. In this paper, the Ni3Al and NiAl high temperature structural materials were summarized. Various properties of Ni3Al and NiAl were
briefly discussed. As well as, various preparations of intermetallics compounds were retrospected. Ni3Al and NiAl alloys have good per-
formance such as high melting point, excellent oxidizability resistance under high temperature, moderate density, outstanding heat and elec-
trical conductivity, which were considered as the outlook high temperature structural materials at the present and become emphasis which
were exploited and researched.

Keywords: high temperature structure materials; Ni3Al; NiAl; intermetallic compound

1. Introduction showed that NiAl，Ni3Al matrix as high temperature struc-

High temperature structural materials stems from need of
the arm force planes in 1940’s. Recently, they could not to
be replaceable and key materials for high temperature gas
turbine engine. High temperature structural materials pos-
sess high strength at high temperature to ensure the engine
using fuel not to be more. They have stronger corrosion re-
sistance, and although they were washed out by high tem-
perature and were eroded by corrosion medium, they kept
their original properties. In the same time, they might work
safely and reliably for a long time. They became important
structure materials for applying to aviation, aeronautic and
astronautic, traffic transportation and chemical mechanism ar-
eas, etc. owing to their properties of enduring high temperature,
corrosion resistance and anti-eroding. They were paid widely
attention to and studied in recently past two decades.
Metallic valence bond and covalent bond co-existed in
intermetallic compounds, meanwhile there were high tough-
ness of metal and ceramic high temperature property for in-
termetallic compounds, then they had widely application
potential . The intermetallic compounds NiAl, Ni3Al matrix
were attracting researchers to study, it was because excellent
anti-corrosion at room temperature. But, crystal rupture was
most biggest obstacle to restrict project application. So it
ture material possessed enormous application potential, and
obvious defects [1-12].
2. Ni3Al intermetallic compound
2.1. Characteristics of Ni3Al intermetallic compound
Ni3Al was long term and order intermetallic compound
which had L12 type crystal structure (see Table 1). It still
held highly order at even nearly its melting point. Constant
of crystal grain was a = 0.3561 nm, melting point was 1390 ºC
Yang module was 180 GN/m2, resistance rate was 32.59 ×
10-8 Ω·m, heat conduct rate was 28.85 W/m/K, Ni3Al inter-
metallic compound had the properties of high the melting
point, higher temperature strength and creep resistance, and
bigger intensity. Moreover with temperature rising high, on
the contrary, its yield strength increasing. Therefore, these
properties were just needed on high temperature structure
materials [13].
2.2. Effect of element doping on Ni3Al properties
(1) Ni3Al toughness grew evidently when solid solution
state doping B amount of the range of 0.02 - 0.1% (wt.%),
and its elongation reached 52%. B content continued in-

Corresponding author: WANG Jingxin E-mail: wangjx1917@126.com

Wang J.X. et al., Research status and progress of NiAl based alloys as high temperature structural materials 423

creased, but Ni3Al toughness decreased slightly. B doping Table 1. Performances of aluminium and boride alloys
15 at.% was proper on Ni3Al comprehensive mechanical tm / ρ/ Crystal E/ρ /
performance. Alloy stoichiometry rate had strongly effect on Alloy
ºC (g/cm3) structure (MN/m/kg)
Ni3Al (B) toughness [14]. B had just only toughness action NiAl 1400 5.9 L12 33
on Ni3Al rich Ni, while it had not any effect on quasi-match Ni3Al 1640 7.5 B2 35
rate Ni3Al, and Ni3Al with rich Al. B had strongly toughness TiAl 1460 3.8 L10 46
effect on Ni3Al at room temperature. At present there were Ti3Al 1600 4.3 D019 34
main two modals: one was modal of B increase cohesion, the FeAl 1250-1400 5.6 B2 47
other was transmitting modal of B driving dislocation to slip [13]. Fe3Al 1540 6.7 D03 27
(2) Effect of the other elements on Ni3Al toughness. MoSi2 2030 6.5 C11b 58
Toughness of Ni3Al doping Be rose up to 6% at room tem-
perature. Be solubility was 1 at.% in Ni3Al, however, when Compound materials with Al2O3 boosting up Ni3Al were
doping Be amount was more than solubility, it could not investigated. Compound materials with Al2O3 boosting up
cause loss of toughness like B. Doping Fe to Ni3Al (doping Ni3Al might be prepared by hot pressure and high extrusion
amount 4% - 5% (atom fraction)), Ni3Al bent toughness en- method, the stretch rate reached up to 10%. Xiao Chengbo
hanced at room temperature. Ni3Al (B) doping Fe was [15] adopted directional concreting to prepare Ni3Al matrix
higher toughness than Ni3Al doping Fe. Mn could enhance high structure material IC6A alloy. Studies results showed
Ni3Al toughness at room temperature, and reduce gap sensi- that Ni3Al high temperature oxidation resistance rose obvi-
tivity. Zr could improve Ni3Al toughness at room tempera- ously. The high temperature enduring property, creeping re-
ture and medium temperature. Then different from B affect- sistance property, impacting property, high temperature heat
ing Ni3Al toughness, Zr had not only tough action on Ni3Al fatigue property and high frequency fatigue property were
with rich Ni, but the same tough action as Ni3Al with rich Al, better than that of IC6 alloy owing to proper amount of Y
Zr, Hf solid solution strengthening improved creeping prop- doping. IC6 alloy proper to make guiding blade of
erty. Hf strengthening effect was the most obvious. The dif- aero-engine which works at 1100 ºC.
ference of radii was biggest between Hf and Ni atoms.
From Fig. 1 it could be seen that Hf had strengthening,
meanwhile, strengthening effect was the best at high tem- 3. NiAl Intermetallic alloy
perature [1]. Adding Cr could enhance oxidation resistance. 3.1. Basic property of NiAl intermetallic alloy
Especially, studies by several years, it could be found that
single phase Ni3Al (B) added about 8% Cr to become dou- The structure of NiAl alloy was body-centered cubic (bcc)
ble phase Ni3Al (B)-Cr matrix alloy. Therefore Ni3Al (B) lattice (seen Table 1) [13]. It was difficult to solve brittle of
had better room plasticity and had medium temperature dy- room temperature, result in its research lagged from Ni3Al.
however, its melting point was high (1640 ºC), specific den-
namic brittle potential. Simultaneity, double phase was
stronger than single phase at creep resistance. Oak Ridge sity was very low (5.9 g/cm3), and oxidation resistance was
National Laboratory of America intermetallic matrix devel- very strong. So it was hopeful as high temperature material
of aeronautic and astronautic engine. However, there was
oped Ni3Al (B)-Cr metal compound IC 218. These alloys
were direct of business development .and they could applied still large distance to reach practicality as a result of brittle
to parts of gas turbine, exchanger parts of automobile, and as multi-crystal and low mechanical strength above 500 ºC
(seen Table 2).
so on(see Table 1).
3.2. Effect of adding elements on NiAl properties
Intermetallic compound inevitably occurred oxidation to
form oxidation film at high temperature surrounding to re-
sult in material becoming brittle. Currently, the main way
for improving oxidation resistance was to add alloying ele-
ments. Adding elements were of easy oxidation to produce
the compact surface oxidation layer which prevented air
atoms to disperse to the alloy, thereby it could be seen that
protects material. The oxides adding element were more sta-
ble than that of any elements of the alloy, so adding ele-
ments were oxidize in advance. Furthermore, adding ele-
Fig. 1. Effect of Hf on elongation and yield stress of Ni3Al.
424 RARE METALS, Vol. 30, Spec. Issue, Mar 2011

Table 2. Properties of materials for turbine engine

ρ/ E/ KIC / Auti-creepage Anti oxidation
Materials
(g/cm3) GPa (MPa·M1/2) temperature limit / ºC temperature limit / ºC
Ti alloy 4.5 110 35 - 60 600 600
Ni alloy 8.3 125 30 - 35 1100 1100
α-Ti3Al 4.3 145 25 800 650
γ-TiAl 3.8 176 25 950 900
NiAl co-crystal 5.9 193 12 - 15 1100 －
MoSi2 6.5 379 4.5 － >1700
Nb10%Si (atom fraction) 7.5 145 25 － ～400

ments should be proper amount in order to form the con-

tinue protecting layer.
The microstructure of the tested alloy as-cast includes γ′-
Ni3(Al,Cr), β-Ni(Al, Cr) and α-Cr phase. The microstructure
consisted of equiaxed primary β-NiAl with mean grain size
of 3 - 5 μm and elongated eutectic colonies along the extru-
sion direction after hot-extruded. The results showed the
BDT behavior of the tested alloy was typically dependent on
the parameter of strain rate and temperature. At the tem-
peratures below BDTT, the fracture surfaces were charac-
terized by complete debonding along the β/γ′ interface;
above BDTT, the fracture surfaces become ductile with a
large amount of cracks. It was proposed that the debonding Fig. 3 Relation between tensile elongation and tested tem-
of the ductile phase β/γ′ was growing from the poorstrength perature around the BDTT for NiAl-25Cr alloy as extruded.
of the phase boundary (seen Figs. 2, 3) [16].
Nb could strengthen crystal boundary, and toughness grew 4
NiAl alloy adding Ni2AlTi phase formed double phase
times than that of without Ti or Nb.
compound, which strength enhanced evidently, and stronger
The creep property of NiAl was improved by adding al-
than that of Mar-M200 Ni alloy applying turbine blade in
loying elements. NiAl producing second phase, when alloy-
project. Therefore, it was attractive foreground. Plasticity of
ing elements exceeded solubility limit, which made creep
multi-crystal NiAl was improved by refining crystal grain,
property enhanced the most. NiAl with TiS2, Al2O3, HfC,
for example, NiAl adding Fe might boosted (111) slipping.
etc. grain intensified attained NiAl matrix composite materi-
Experimental showed that granularity of NiAl existed a
als. The oxidation resistance of NiAl was stronger than that
critical size of brittle conversion, which was 3 μm at room
of Ni matrix super alloy. Adding Cr, Zr, Y, NiAl could
temperature. However, fine crystal structure makes again
make for forming surface protection layer of Al2O3 to im-
creep resistance at high temperature NiAl adding 5%Ti or
prove oxidation resistance obviously.
Peng Bing pointed that the geometrical and electronic
structures of NiAl supercells were calculated by the first-
principlepseudopotential plane wave methods based on the
density functional theory. Several mechanical parameters
were used to characterize and assess the alloying effect of
the element on the brittle or ductile behavior as well as the
hardness of NiAl intermetallic compounds. The result
showed that addition of Cr or Mn, Fe, Co, Cu could enhance
the hardness of compounds in the following order: Cu, Cr,
Fe, Co, Mn, but the ductility of compounds decreased with
an opposite order to the increase of their hardness because of
their high contents of addition (eg.6.25%, atom fraction) [17].
Fig. 2. True stress strain curves around the BDTT for NiAl depositing Ni3Al might improve toughness. When
NiAl-25Cr alloy as extruded. adding Fe to NiAl alloy, it could form double phase struc-
Wang J.X. et al., Research status and progress of NiAl based alloys as high temperature structural materials
ture (Ni, Fe)(Fe, Al) and (Ni, Fe)3(Fe, Al) to increase yield
strength. NiAl adding Ta, Nb deposited second phase to gain
strength. Moreover, NiAl also heightened strength through
mechanical alloying technics adding grain of oxide (Y2O3,
Al2O3, ThO2) or TiB2.
4. Preparation technology
The same as the other intermetallic compounds, prepara-
tion methods of NiAl, Ni3Al had conventional methods,
such as smelt casting, powder metallurgy, directional solidi-
fication, etc. Moreover, new technology methods were de-
veloped nowadays [18-22].
(1) Rapidly solidification: this was a method that solidifi-
cation technology combines with powder metallurgy. Alloy
powder was atomized by spin plate, and plasma spin elec-
trode or air atomized process. then, NiAl, Ni3Al compounds
were packaged by stainless steel or carbon steel, the package
with NiAl, Ni3Al compounds through drying, dumping,
sealing, in addition, re-heat extruding to molding, or heat
wasostatics pressing Ceracon concretion method.
(2) Spontaneous combustion high temperature synthesiz-
ing method: The chemical reactions occured among the dif-
ferent substances, which utilizes self-conducting action of
substance reaction heat. It was a high temperature synthe-
sizing method: that formed compound during shorter time
(about 1 s).
(3) Element powder method: various elements consisting
compound were mixed according to stoichiometry. Then,
density reached over 95% with vacuum heat pressing, and,
heat pressing billet at the further for turning to component
which the lowest density approached nearly theory density.
The kind of product should meet elective elements high pu-
rity, hydrogenous and oxygen content low, because impurity
results in significantly brittle on intermetallic compound.
Therefore, clean environment was required in work process,
such as powder treatment, mixture bag packaging, and
pressing courses, etc.
(4) Shock-wave molding: this molding was a cooling
process which adopts dynamic solidity technology. The
compound powder was put into two coaxial round barrels
firstly in the molding process, the round barrels were parked
in the sealed equipment. The shocking wave was produced
by igniting and blasting to oppress powder in the barrels,
and finally powder solidified in the shorter time.
(5) Super plasticity molding: this method utility material
had super plasticity in the range of temperature and strain
rate to make material mold. It was very effective for hard
deformation intermetallic compound. How intermetallic
compound adopted super plasticity, the key was that inter-
metallic compound should have super fine grain and elect-
425
ing proper deformation temperature and rate. Currently,
Ni3Al turbine plate with shape complex was succeeded in
manufacturing by adopting this technology.
(6) Electron beam physical vapor deposited (PVD): this
method took electron beam as heat source, utilizes high
speed electrons to bombard surface of materials. Then, the
materials risen temperature turns into stream and agglomer-
ates on surface of matrix [7-10].
5. Conclusion
High temperature structure materials become not to be re-
placeable for military and civilian high turbine engine.
Ni-Al intermetallic compound was a kind of important ma-
terial in field of material science. Currently, it got along with
primary phase. of application, it could be well known that
research for aspects of mechanism of high temperature oxi-
dation resistance should be enhanced, and reducing brittle at
the further, and boosting plasticity, and so on. New Ni-Al
high temperature structure materials could substitute for that
of the weaker contrasting strength in the near future for all
means.
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