This paper reviews our current research activities on developing new multiphase metallic materials for structural applications with a temperature capability beyond 1,200°C. Two promising material systems have been chosen: first, alloys in the system Mo-Si-B which have demonstrated potential due to their high melting point of around 2,000°C and due to the formation of a protecting borosilicate glass layer on the surface at temperatures exceeding 900°C; and second, novel Co-Re-based alloys which have been chosen as a model system for complete miscibility between the elements cobalt and rhenium, offering the possibility of continuous increases of the melting point of the alloy through rhenium additions.

Metallic materials for structural applications beyond nickel-based superalloys

A dislocation density based material model to simulate the anisotropic creep behavior of single-phase and two-phase single crystals

High-temperature oxidation behavior of Mo–Si–B-based and Co–Re–Cr-based alloys

Effects of Si additions on microstructures and mechanical properties of VNbTiTaSi refractory high-entropy alloys

The effects of boron addition on the microstructure and mechanical properties of Co–Re-based high-temperature alloys

Ni-based superalloys are the dominant material class in the hot section of gas turbines. This is so, because they uniquely combine three key properties at a favourable performance to cost ratio: toughness, strength at elevated temperature and oxidation resistance. However, there is also an important limitation. Given gas temperatures in excess of 1500 °C and peak material temperatures of up to 1100 °C, the latter are already very close to the melting point of superalloys at around 1300 °C. It is very likely that material development will continue to push the maximum allowable service temperature of superalloys upwards. However, there is a limit and given the long term nature of material development, it is essential to search now for solutions beyond the temperature capability of Ni-based superalloys. For this reason, substantial international research is underway, focussing on ceramics, intermetallic materials such as NiAl, refractory metals such as Nb-based and Mo-based alloys, as well as noble metals mimicking the c/c′-microstructure of superalloys. The difficulty faced in all these new developments is that these materials have at least one pronounced weakness regarding the above mentioned key properties, and the challenge is to find acceptable solutions. In fact, there is substantial progress. For example, much improved oxidation resistance has been reported for certain refractory alloys and significant patent activity is noticeable in this field. Nevertheless, none of the evaluated material systems has come to the point were an acceptable property mix has been reached, allowing for demanding applications in the hot section of gas turbines. For this reason, it seems sensible to further search for alternative solutions, which have not been explored so far. One, namely the development of Co-Re-based high temperature alloys, is addressed here and the article is structured as follows. Firstly, the rational for focussing on Co-Re-based alloys is given. Four alloys are then evaluated to gain first insight in the microstructure evolution of this material class. Finally, these results are summarized and directions for further alloy development are discussed.

Co‐Re‐based Alloys: A New Class of High Temperature Materials?

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Co‐Re‐based Alloys: A New Class of High Temperature Materials?