The manufacture of ground heavy-duty gas turbines, ship-borne gas turbines, and aircraft engines urgently needs alloy materials that are self-controlled and have excellent high-temperature strength. As the service temperature of the hot end components of this equipment gradually increases, traditional high-temperature resistant alloys are difficult to adapt to such high service temperatures, and metal structural materials for ultra-high temperature service environments are in urgent need of development.
Ultra-high temperature metal structural materials refer to metal materials with a strength of more than 150 MPa under a temperature environment above 1650°C, which need to meet the dual indicators of temperature and strength at the same time. Refractory high entropy alloys have the advantages of high melting points, high-temperature resistance, and high strength. They are mainly composed of high melting point metal elements such as niobium, molybdenum, tantalum, tungsten, hafnium, rhenium, vanadium, zirconium, and titanium, as well as non-metallic elements such as nitrogen, carbon, and silicon. They have great potential for ultra-high temperature applications and have received widespread attention from the scientific community in recent years.
Ultra-high temperature metal structural materials
The researchers designed a niobium, molybdenum, tantalum, tungsten, hafnium, nitrogen refractory high entropy alloy with potential ultra-high temperature engineering application prospects by regulating the in-situ generation of multi-component nitrides and introducing the generated multi-component nitrides as strengthening phases into the niobium, molybdenum, tantalum, tungsten, hafnium, nitrogen refractory high entropy alloy. This alloy has extremely high strength in the range of 1000℃ to 1800℃, and the strength can reach 288 MPa at 1800℃, achieving both high-temperature resistance and high strength.
The research team found that the niobium, molybdenum, tantalum, tungsten, hafnium, and nitrogen refractory high entropy alloys far exceed most alloys in terms of both test temperature and high-temperature strength. This excellent performance makes it have a wide range of engineering application potential at ultra-high temperatures, and can be used in aviation engine engineering and ground gas turbine engineering.
The refractory high entropy alloy they studied and designed has roughly the same content of each element and is a metal material with a simple crystal structure. At present, the research team has not only prepared 10 kg niobium, molybdenum, tantalum, tungsten, hafnium, and nitrogen refractory high entropy alloy ingots but also obtained a large number of alloy powders. Through laser additive manufacturing technology, large-size niobium, molybdenum, tantalum, tungsten, hafnium, and nitrogen refractory high entropy alloy structural parts can be directly printed.
Currently, most aircraft engines and ground heavy-duty gas turbines use cast high-temperature alloy blades, which are thermally insulated and air-cooled by TBC thermal barrier coatings and air film holes. The alloy material they developed is suitable for high-temperature environments exceeding 1650°C, which may help in the manufacture of aircraft engines or heavy-duty gas turbine turbine blades.
High Temperature Coatings
Spherical niobium powder is used to produce nickel, chromium, and iron-based high-temperature alloys.
Advantages of spherical morphology
Compared with traditional irregular powders, spherical niobium powder has higher fluidity and filling properties, which is particularly important in the manufacturing process of complex-shaped parts. Good fluidity ensures that the powder is evenly distributed when injected into the mold, reducing the generation of voids and defects. At the same time, high-filling properties help to improve the density and strength of the parts, making the final product more dense and stable in performance.
Strengthening agent for nickel-based superalloys
In nickel-based superalloys, spherical niobium powder plays the role of strengthening element. The addition of niobium can significantly improve the creep strength and heat resistance of the alloy, especially in high-temperature environments; niobium can effectively inhibit grain boundary sliding and phase transformation, thereby delaying the structural degradation of the material. This is the key to increasing the operating temperature and extending the service life for key components such as turbine blades and combustion chambers of aircraft engines.
High-performance additive for chromium and iron-based alloys
For chromium and iron-based superalloys, spherical niobium powder also plays a reinforcing role. In these alloy systems, niobium can refine the grains, improve the tensile strength and wear resistance of the material, and also improve its oxidation resistance and corrosion resistance. This is of great significance for components that need to work in harsh chemical environments or high-temperature conditions, such as reactor linings in the petrochemical industry and high-temperature components in power plants.
Preparation technology and challenges
The preparation of spherical niobium powder usually involves advanced technologies such as gas atomization, rotating electrode method, or plasma rotating electrode method. These methods can control the particle size distribution while ensuring the sphericity of the powder to meet the needs of different applications. However, how to maintain powder consistency and reduce costs in large-scale production remains one of the main challenges currently faced.
Spherical Niobium Powder Ni Powder
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