Microstructure and mechanical properties of oxidation resistant suction cast Nb–Si–Al alloy

In this paper, we report a significant improvement in mechanical and oxidation properties of near eutectic Nb–Si alloys by the addition of aluminum (Al) and control of microstructural length scale. A comparative study of two alloys Nb-18.79at%Si and Nb-12.3at%Si-9at%Al were carried out. The processing for microstructure refinements were carried out by vacuum suction casting in water cooled thick copper mould. It is shown that addition of Al suppresses Nb3Si phase and promotes βNb5Si3 phase under nonequilibrium solidification condition. The microstructural length scale and in particular eutectic spacing reduces significantly to 50–100 nm in suction cast ternary alloy. A detailed TEM study shows the presence of δ-Nb11Si4 phase in Nb matrix. The hardness of Nb solid solution can be increased as a consequence to a level observed in Nb3Si intermetallic due to the well oriented precipitates. Compression test yields the ultimate strength of 1.8±0.1 GPa and engineering strain of 2.3±0.03%. In comparison, the binary Nb-18.79 at% Si alloy possesses an ultimate strength of 1.35±0.1 GPa and strain of 0.2±0.01% when processed under identical conditions. The latter exhibits coarser microstructural length scale (300–400 nm) and a brittle behavior. The indentation fracture toughness of Al containing suction cast alloy shows a value of 20.2±0.5 MPa√m which represents a major improvement over bulk Nb–Si eutectic alloy. The detailed thermal studies confirm a multifold improvement in oxidation resistance up to 1000 °C.