Thickness Effects on Oxidation Behavior and Consequent γ’ Degradation of a High-Al Ni-Based Single Crystal Superalloy

High temperature oxidation is considered to play an essential role in the thickness debit effect on the creep rupture life of Ni-based single crystal (SC) superalloys. In order to clarify thickness effects, thin-walled specimens of different thickness (t = 0.1, 0.3, 1.0 mm) were prepared. Cyclic and isothermal oxidation tests of a high-Al Ni-based SC superalloy IC21 were carried out at 900 °C and 1100 °C in order to study the thickness effects on the oxidation behavior and consequent microstructural degradation. Thin-walled specimens of S01-N exhibited a good oxidation resistance when the protective scale-forming elements were enough in the matrix. Specimen thickness tuned the oxidation kinetics by changing the spallation behavior but had few influences on the thermodynamics. The easier stress relief via creep deformation in thin specimens is the main reason behind this phenomenon. Moreover, the obvious temperature effects on the multilayer oxide scales caused the different thickness-related spallation behaviors. Weaker microstructural degradation appeared and was further mitigated by reduced specimen thickness. Sufficient Al content is considered to be indispensable for the formation of protective α-Al₂O₃ scale with less degradation of matrix during the high temperature oxidation of thin-walled Ni-based SC superalloy castings.