J. R. Crum, B. A. Baker, R. S. Parsons, Special Metals Corporation, Huntington, WV
Examples of important nickel alloy thin sheet applications for aircraft engines include exhaust ducting and abradable honeycomb seals. These components may operate at very high temperatures, resulting in possible severe oxidation attack. In thin sheet the oxidation rate can be the critical factor in determining useful life of the material. Measuring oxidation rate by mass loss alone can be misleading, while total depth of attack measurements are much more meaningful. Oxidation testing of several stainless steels, nickel alloys and cobalt alloys has been conducted for up to 2000 hours at temperatures up to 1100° C with periodic mass loss and depth of attack measurements. In some cases depth of attack measurements reveal poor performance while corresponding mass loss results indicate only moderate attack. Beneficial effects of minor additions of aluminum, silicon and rare earth elements and detrimental effects of niobium, as well as the need for a substantial "chromium reservoir" for continuous oxide repair are demonstrated. Effects of high temperature fatigue are also addressed and data for a new lower cost nickel alloy are presented. Finally, overall high temperature performance relative to alloy cost is evaluated.
Summary: The high temperature oxidation resistance of various nickel and cobalt alloys are evaluated for thin sheet applications in aircraft engines. Both mass loss and depth of attack are used in 2000 hour tests to evaluate degree of degradation. Overall performance, relative to materials cost, is reviewed and a new lower cost nickel alloy is examined.