After almost three decades of intensive fundamental research and development activities intermetallic titanium aluminides based on the -TiAl phase have found applications in automotive and aircraft engine industries. The advantages of this class of innovative high-temperature materials are their low density as well as their good strength and creep properties up to 750°C. A drawback, however, is their limited ductility at room temperature, which is reflected by a low plastic strain at fracture. This behavior can be attributed to a limited dislocation movement along with microstructural inhomogeneity. Advanced TiAl alloys, such as β-solidifying TNM™ alloys, are complex multi-phase materials which can be processed by ingot or powder metallurgy as well as precision casting methods. Each production process leads to specific microstructures which can be altered and optimized by thermo-mechanical processing and/or subsequent heat-treatments. The background of these heat-treatments is at least twofold, i.e. concurrent increase of ductility at room temperature and creep strength at elevated temperature. In order to achieve this goal the knowledge of the occurring solidification processes and phase transformation sequences is essential. Therefore, thermodynamic calculations were conducted to predict phase fraction diagrams of engineering TiAl alloys. After experimental verification, these phase diagrams provided the base for the development of heat treatments to adjust balanced mechanical properties. To determine the influence of deformation and kinetic aspects, sophisticated ex- and in-situ methods have been employed to investigate the evolution of the microstructure during thermo-mechanical processing and subsequent multi-step heat-treatments. For example, in-situ high-energy X-ray diffraction was conducted to study dynamic recovery and recrystallization processes during hot-deformation tests. Summarizing all results a consistent picture regarding microstructure formation and its impact on mechanical properties in TNM alloys can be given.

The processing of a TNM powder (Ti-43.9Al-4Nb-0.95Mo-0.1B, in at.%) by Spark Plasma Sintering (SPS) was investigated for the first time. SPS experiments were performed at varying temperatures. The microstructures of the products were analyzed and interpreted in reference to the available phase diagram. Results of tensile tests conducted at room temperature are also presented.

Balanced mechanical properties are needed for TiAl low pressure turbine blades envisaged for use in new generation aircraft engines. However, thermomechanical processing of γ-TiAl based alloys is a challenging task due to a small “processing window”. Isothermal forging, as state of the art process for this class of material, results in high productions costs and lower productivity. Due to these facts Bohler Schmiedetechnik GmbH & Co KG has developed a higher efficient “near conventional” thermomechanical processing technology. Lower die temperature and processing at standard atmosphere as well as the use of standard hydraulic presses with higher ram speed result in a highly economical process. Subsequent heat treatment strategies can be used to tailor microstructure and, therefore, mechanical properties according to customer needs. The paper summarizes our effort to establish a near conventional forging route for the fabrication of TiAl components for aerospace industry.

A robust processing route at low cost is an essential requirement for high-temperature materials used in automotive engines. Because of their excellent high-temperature properties, their low density, high elastic modulus as well as high specific strength, intermetallic γ-TiAl based alloys are potential candidates for application in advanced automotive turbochargers. So-called 3rd generation alloys, such as TNM™ alloys with a nominal composition of Ti-43.5Al-4Nb-1Mo-0.1B (in at%), are multi-phase alloys consisting of γ-TiAl, α2-Ti3Al and a low volume fraction of βo-TiAl phase. In this paper a novel hot-processing route, which is a combination of a one-shot hot-forging step and a controlled cooling treatment, leads to mechanical properties required for turbocharger turbine wheels. The observed strength can be attributed to the small lamellar spacing within the α2/γ colonies of the nearly lamellar microstructure. In order to analyze the microstructure and the prevailing phase fractions microscopic examinations and X-ray diffraction measurements were conducted. The mechanical properties were determined by hardness measurements as well as tensile and creep tests. The evolution of the microstructure during the hot-forming process is described and its relation to the obtained mechanical properties.

Intermetallic TiAl alloys are of interest to the aero engine industry because of their light weight, corrosion resistance and excellent high temperature strength. This justifies the continued effort to improve properties and processing of these alloys.

A critical parameter that limits the practical implementation of Ti aluminides is their low ductility at room temperature. Recently, a new class of TiAl alloys based on a modulated lath structure has been introduced that exhibit an excellent combination of ductility and strength. A key component in this alloy is the orthorhombic phase B19 that is attributed to alloying with high amounts of niobium. The driving forces and mechanisms that lead to the observed modulated structures involving the B19 phase are not fully understood yet. As a first step to a better understanding we present a study of the thermal stability range of the phases involved.

In the last decades there was a growing interest in developing new light-weight intermetallic alloys, which are able to substitute the heavy superalloys at a certain temperature range. At present a new Ti-Al-Nb-Mo family, called TNM™ alloys, is being optimized to fulfill the challenging requirements. The aim of the present work was to study the microscopic mechanisms of defect mobility at high temperature in TNM alloys in order to contribute to the understanding of their influence on the mechanical properties and hence to promote the further optimization of these alloys. Mechanical spectroscopy has been used to study the internal friction and the dynamic modulus up to 1460 K of a TNM alloy under different thermal treatments. These measurements allow to follow the microstructural evolution during in-situ thermal treatments. A relaxation process has been observed at about 1050 K and was characterized as a function of temperature and frequency in order to obtain the activation parameters of the responsible mechanism. In particular, the activation enthalpy has been determined to be H= 3 eV. The results are discussed and an atomic mechanism is proposed to explain the observed relaxation process.

The present article will describe the science and technology of titanium aluminide (TiAl) alloys and the engineering development of TiAl for commercial aircraft engine applications. The GEnxTM engine is the first commercial aircraft engine that is flying titanium aluminide (alloy 4822) blades and it represents a major advance in propulsion efficiency, realizing a 20% reduction in fuel consumption, a 50% reduction in noise, and an 80% reduction in NOx emissions compared with prior engines in its class. The GEnxTM uses the latest materials and design processes to reduce weight, improve performance, and reduce maintenance costs.

GE’s TiAl low-pressure turbine blade production status will be discussed along with the history of implementation. In 2006, GE began to explore near net shape casting as an alternative to the initial overstock conventional gravity casting plus machining approach. To date, more than 40,000 TiAl low-pressure turbine blades have been manufactured for the GEnxTM 1B (Boeing 787) and the GEnxTM 2B (Boeing 747-8) applications. The implementation of TiAl in other GE and non-GE engines will also be discussed.

The CALPHAD (CALculation of PHAse Diagrams) method is widely recognized as a powerful tool in both scientific and industrial development of new materials and processes. For the implementation of consistent databases, where each phase is described separately, models are used which are based on physical principles and parameters assessed from experimental data. Such a database makes it possible to perform realistic calculations of thermodynamic properties of multi-component systems. However, a commercial available TiAl database can be applied for thermodynamic calculations to both conventional Ti-base alloys and complex intermetallic TiAl alloys to describe experimentally evaluated phase fractions as a function of temperature. In the present study calculations were done for a β-solidifying TiAl alloy with a nominal composition of Ti-43.5Al-4Nb-1Mo-0.1B (in at. %), termed TNMTM alloy. At room temperature this alloy consists of ordered γ-TiAl, α2-Ti3Al and β0-TiAl phases. At a certain temperature α2 and β0 disorder to α and β, respectively. Using the commercial database the thermodynamic calculations reflect only qualitative trends of phase fractions as a function of temperature. For more exact quantitative calculations the commercial available thermodynamic database had to be improved for TiAl alloys with high Nb (and Mo) contents, as recently reported for Nb-rich γ-TiAl alloys. Therefore, the database was modified by experimentally evaluated phase fractions obtained from quantitative microstructure analysis of light-optical and scanning electron micrographs as well as conventional X-ray diffraction after long-term heat treatments and by means of in-situ highenergy X-ray diffraction experiments. Based on the CALPHAD-conform thermodynamic assessment, the optimized database can now be used to correctly predict the phase equilibria of this multi-component alloying system, which is of interest for applications in automotive and aircraft engine industry.

The effect of stress on the deformation and crack nucleation and propagation mechanisms of a γ-TiAl intermetallic alloy (Ti-45Al-2Nb-2Mn (at.%) - 0.8v.%TiB2) was studied by means of in situ tensile (constant strain rate) and tensile-creep (constant load) experiments performed at 973 K inside a scanning electron microscope (SEM). The evolution of the microstructure and the nucleation and propagation of cracks was tracked during the high temperature mechanical tests in the SEM. Colony boundary crack nucleation was found to be activated during the secondary stage in creep tests at 300 MPa and 400 MPa and during the tertiary stage of the creep tests performed at higher stresses and at constant strain rate. Interlamellar ledges were only observed during the high stress tensile-creep tests (σ>400 MPa) and during the constant strain rate test. Quantitative measurements of the nature of the crack propagation path along secondary cracks and along the primary crack were carried out. It was found that colony boundaries were preferential sites for crack propagation under all the conditions investigated. The frequency of interlamellar cracking increased with increasing stress.

The development of suitable hot-forming processes, e.g. forging, is an important step towards the serial production of TiAl parts. Several microstructure parameters change during hot-forming. However, the underlying mechanisms can normally only be inferred from post process metallographic studies.

We used a deformation dilatometer modified for working in the HZG synchrotron beamlines at DESY for hot-deformation experiments. This setup enables the in situ monitoring of the interaction and evolution of microstructure parameters during processing. We observed the evolution of phase fractions, grain size and crystallographic texture during deformation while simultaneously recording the process parameters, like temperature, force and length change.

Here we present the hot compressive deformation behaviour of a Ti-43Al-4Nb-1Mo-0.1B (in at.%) alloy. Several specimens were deformed at three temperatures each with two compression rates. During the experiments the Debye-Scherrer diffraction rings were continuously recorded.

Above 750-800°C oxidation becomes a serious life time issue for the new group of intermetallic light-weight high temperature alloys based on titanium aluminides (TiAl). Fast growing titanium oxide competes with protective alumina as a surface scale in the oxidation reaction by which the formation of a slow-growing protective oxide scale is prevented. The key to the development of alloys with sufficient oxidation resistance is the understanding of the thermodynamic and kinetic situation during the oxidation process. The latter is influenced by the type of alloying elements, the Al- and Ti-activities in the alloy, the oxidation temperature and the environment (e.g. dry or humid air, etc.). This paper provides a comprehensive summary of the oxidation mechanisms and the parameters influencing oxide scale formation. Besides the role of metallic alloying elements, the halogen effect will also be discussed. The paper finishes with recent results concerning the prevention of oxidation-induced room temperature embrittlement of TiAl alloys.

The oxidation behavior of γ-TiAl specimens coated with an intermetallic Ti-49Al-34Cr-4Zr layer was investigated at 1000°C under cyclic conditions in laboratory air. The 11 μm thick coating was produced using a combined technique of high power impulse magnetron sputtering and unbalanced magnetron sputtering. The as-deposited coating exhibited a dense layered structure and excellent adhesion to the substrate. The Ti-Al-Cr-Zr coating possessed high oxidation resistance associated with the formation of a thin continuous alumina scale for exposure time periods exceeding 1000 cycles of 1 h dwell time at 1000°C. During the high temperature exposure, the coating being amorphous in the as-deposited condition became crystalline exhibiting different polytypes of Ti(Cr,Al)2Laves phases with Ti probably partially substituted by Zr and Nb. Due to alumina formation and interdiffusion the coating was depleted in aluminum and chromium as well as enriched in titanium. After 1000 cycles at 1000°C, the coating consisted of an outer layer of the hexagonal C14 Laves phase and an inner layer of a probably orthorhombic phase whose structure was not yet determined. In both layers, pores and fine precipitates rich in Zr and Y were found.

Intermetallic titanium aluminides are potential materials for application in high temperature components. In particular, alloys solidifying via the β-phase are of great interest because they possess a significant volume fraction of the disordered body-centered cubic β-phase at elevated temperatures ensuring good processing characteristics during hot-working. Nevertheless, their practical use at temperatures as high as 800°C requires improvements of the oxidation resistance. This paper reports on the fluorine effect on a multi-phase TiAl-alloy in the cast and hot-isostatically pressed condition at 800°C in air. The behavior of the so-called TNM material (Ti-43.5Al-4Nb-1Mo-0.1B, in at %) was compared with that of two other TiAl-alloys which are Nb-free and contain different amounts of Mo (3 and 7 at%, respectively). The oxidation resistance of the fluorine treated samples was significantly improved compared to the untreated samples. After fluorine treatment all alloys exhibit slow alumina kinetics indicating a positive fluorine effect. Results of isothermal and thermocyclic oxidation tests at 800°C in air are presented and discussed in the view of composition and microstructure of the TiAl-alloys investigated, along with the impact of the fluorine effect on the oxidation resistance of these materials.

The pin-on-disc wear behavior of nanostructured two-phase Fe30Ni20Mn20Al30 and eutectic lamellar-structured Fe30Ni20Mn35Al15 is compared emphasizing the influence of the microstructure and mechanical properties of alloys as well as the effect of test environment. Although the wear of both alloys was greater in oxygen-containing environments, eutectic Fe30Ni20Mn35Al15 is less sensitive to oxygen than nanostructured Fe30Ni20Mn20Al30. Abrasive wear dominated during the wear in all cases, while plastic deformation also occurred during the wear of eutectic Fe30Ni20Mn35Al15. A tribolayer of zirconia, which was embedded in the surface of the wear pin, was characterized using a scanning transmission electron microscope equipped with an energy dispersive spectrometer.

Recently, Nb-Si based alloys have attracted considerable attention as potential candidate materials for ultra-high temperature applications, because of their low densities and high melting points. However, it is still very difficult to obtain materials with a good balance of high-temperature strength and room-temperature toughness. To address this issue, microstructure control is considered to be a promising method. In applying microstructure control to Nb-Si based alloys with a eutectic reaction (L → Nbss + Nb3Si) and a eutectoid reaction (Nb3Si → Nbss + Nb5Si3), the key is the control of Nb3Si phase stability. Nbss (Nb solid solution) is considered as a ductile phase. In previous reports, it was revealed that different elements had different effects on the stability of Nb3Si. In particular, Mo and W (>3 at %) destabilize the Nb3Si phase, while Ti and Ta stabilize it, and Zr acts as an accelerator for decomposition of Nb3Si. On the other hand, Cr is known to enhance the formation of the ductile Nbss phase. In the present study, we investigated the effects of adding combinations of stabilizing, destabilizing, and accelerating elements with Cr, such as Cr and W, Cr and Ta, Cr and Zr. According to SEM observation, different microstructures were obtained with different combination of additives, and the fracture toughness at room temperature of these samples were also evaluated to reveal the effects of the microstructure on the mechanical properties of Nb-Si based alloys.

In this study, aluminized, boronized, chromized and siliconized gray cast iron plate specimens were prepared, and their microstructures and tribological properties were investigated. The surfaces of the aluminized, boronized, chromized and siliconized specimens mainly consisted of FeAl, Fe2B, (Cr, Fe)23C6 and FeSi phases, respectively. Also, the surface of the boronized specimen exhibited the highest microvickers hardness of all the specimens. The aluminized, boronized and chromized specimens exhibited friction coefficients as low as the non-coated specimens when sliding against AISI 52100 steel ball specimens in poly-alpha-olefin. In addition, the boronized and chromized specimens exhibited much higher wear resistance than the non-coated specimens.

A Ni3(Si,Ti) intermetalic alloy was synthesized by the powder metallurgy method using elemental powders. The raw powder mixtures with various compositions were sintered by a spark plasma sintering apparatus and then homogenized at high temperatures. Microstructure, hardness, tensile properties and density of the sintered alloys were investigated as functions of the chemical composition and sintering temperature. It was found that a highly-densified Ni3(Si,Ti) sintered alloy was obtained by choosing proper chemical composition and sintering temperature. Also, the Ni3(Si,Ti) sintered alloy with an L12 single-phase microstructure exhibited high hardness and tensile strength.

The objective of this study is to establish alloy designing which can reduce the amount of V for a Ni-base dual two-phase intermetallic alloy, without degenerating the dual two-phase microstructure. It was demonstrated that the favorable dual two-phase microstructure will be maintained as far as the valence electron concentration (e/a) of the alloys added by Cr is not so much different from that of the base alloy (i.e. the alloy without additive elements). Consequently, it was found that the dual two-phase microstructure was maintained even though the amounts of V were reduced by 7 at.%, 7 at.%, and 10at.% by substituting of Cr for V, Cr for both of Ni and V, and Cr for Ni, respectively. The hardness of the alloys with reduced V content was higher than that of the base alloy.

The effect of Re addition on microstructure and hardness of the Ni3Al (L12) and Ni3V (D022) dual two-phase intermetallic alloys was investigated as functions of alloying (substituting) method of Re and aging condition (temperature and time). Re was added to the base alloy composition by three methods: Re was substituted for Ni, Al and V, respectively. The Re-added alloys were solution-treated at 1553 K and then aged at lower temperatures of 1123 K-1248 K. Apparent age hardening occurred in the alloy where Re was substituted for Ni while no age hardening was observed in the alloys where Re was substituted for Al or V. In the case of the latter two alloys, the hardness was unchanged or reduced with a progression of aging time. These results were discussed in terms of phase separation and ordering in the channel region, and hardening due to Re-rich phase precipitation.

In order to develop NiMnGa/polymer composite materials, a production of single-crystal-like NiMnGa particles is important and should be developed for better quality. Although mechanical pulverization is a promising method by utilizing intrinsic intergranular brittleness of NiMnGa polycrystalline ingots, the amount of lattice defects introduced during mechanical crushing needs to be minimized. This must be achieved by enhancement of intergranular brittleness of NiMnGa particles. In this study, the effect of Bi addition on the compressive fracture behavior of polycrystalline Ni50Mn28Ga22 was investigated where Bi was expected to be segregated to the grain boundaries in NiMnGa, similar to Bi segregation to the grain boundaries in Ni. It was found that only intergranular fracture was observed in Ni50Mn28Ga22 polycrystals with 0.3 at.% Bi addition, although a mixture of intergranular and transgranular fracture was observed in Bi-free Ni50Mn28Ga22 polycrystal. Microalloying of Bi into NiMnGa enhances intergranular embrittlement. A number of spherical particles of Bi were confirmed on the fractured surface of Bi-doped NiMnGa polycrystals. The formation of Bi particles is a proof of the grain boundary segregation of Bi in NiMnGa.