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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Assessment of binary eutectic Ni alloys for high-temperature applications via laser remelting

It has been recently demonstrated that eutectic alloys processed by additive manufacturing have excellent high-temperature mechanical properties. We suggest that nickel-base eutectic alloys may enable new combinations of structural and functional properties. To this end, we investigate the processability, microstructure, and thermal stability of five, binary near-eutectic Ni-X (X = B, Ce, La, Y, and Zr) alloys processed via surface laser-remelting. The microstructure of all alloys contain a two-phase lamellar eutectic microstructure consisting of γ-Ni and intermetallic phases; this microstructure is significantly finer (100–200 nm lamellar spacing) in the laser-remelted alloys than in the cast substrate (0.5–1.0 µm lamellar spacing). The microhardness of the laser-remelted alloys (550–770 HV) is 35–50% higher than that of the cast alloys (370–570 HV) due to this finer eutectic spacing. An anomalous eutectic microstructure appears at the meltpool boundaries, containing globular and lamellar γ-Ni phases. The alloys contain a high volume fraction (>50 vol%) of intermetallic phase which forms a continuous network, causing brittleness. Following laser-remelting trials, the alloys showed a high density of solid-state cracks, except for the Ni-Zr alloy which processed well. During thermal exposure at 700 and 900°C for up to 500 h, the eutectic microstructure coarsens. Coarsening occurs heterogeneously and initiates at the meltpool boundaries. This process occurs more slowly in the Ni-Zr and Ni-Y alloys, and more rapidly in the remaining alloys, resulting in greater microhardness retention in the Ni-Zr and Ni-Y alloys following thermal exposure at 700°C. Thus, among the five alloys, the Ni-Zr system exhibits a good combination of high-temperature mechanical properties and processability. Here, we conclude with recommendations for future work on designing additively manufactured alloys based on these eutectic Ni systems.

Additive manufacturing↗
DOE OSTI2026

Evaluation of high-temperature properties of binary, eutectic Ni-X alloys (X = B, Ca, Ce, La, Y, Zr)

We investigated the high-temperature behavior of binary eutectic nickel-base alloys with low-solubility elements, towards developing alloys with new combinations of structural and functional (e.g. thermal or corrosion) properties. Based on thermodynamic screening, we cast binary near-eutectic Ni-B, Ni-Ca, Ni-Ce, Ni-La, Ni-Y, and Ni-Zr alloys and characterized their microstructure and high-temperature properties. All alloys (except Ni-Ca) contain a fine eutectic microstructure, containing submicron alternating lamellae of γ-Ni and continuous intermetallic phases. The eutectic microstructure did not significantly coarsen at 700°C (except for Ni-B), but measurably coarsened in all alloys at 900°C, most quickly in Ni-B, followed by Ni-Ce, Ni-La, Ni-Y, and Ni-Zr. Coarsening in these alloys occurs by fault migration; diffusion within the intermetallic, and its interfacial energy, likely influence coarsening kinetics. At room-temperature, all alloys possess negligible ductility due to the continuous, brittle intermetallic. At 700 and 900°C, the Ni-Zr alloy showed the best combination of strength and ductility. Oxidation experiments at 900°C on Ni-Zr and Ni-Ce revealed heavy internal oxidation of the continuous intermetallic phase. Overall, the Ni-Zr alloy showed good high-temperature coarsening resistance and strength, though ductility and oxidation resistance require improvement for use in structural applications. Possible routes for improving alloy properties via additive manufacturing are discussed.

Ekaputra, Clement [ORNL] (ORCID:0000000307166479)↗
DOE OSTI2024

Thermo-mechanical behavior of hypoeutectic Ni-Y-Zr alloys

Microstructure refinement and optimized alloying can improve metallic alloy performance: stable nanocrystalline (NC) alloys with immiscible second phases, e.g., Cu-Ta, are stronger than unstable NC alloys and their coarse-grained (CG) counterparts, but higher melting point matrices are needed. Hypoeutectic, CG Ni-Y-Zr alloys were produced via arc-melting to explore their potential as high-performance materials. Microstructures were studied to determine phases present, local composition and length scales, while heat treatments allowed investigating microstructural stability. Alloys had a stable, hierarchical microstructure with ~250 nm ultrafine eutectic, ~10 µm dendritic arm spacing and ~1 mm grain size. Hardness and uniaxial compression tests revealed that mechanical properties of Ni-0.5Y-1.8Zr (in wt%) were comparable to Inconel 617 despite the small alloying additions, due to its hierarchical microstructure. Here, uniaxial compression at 600 °C showed that ternary alloys outperformed Ni-Zr and Ni-Y binary alloys in flow stress and hardening rates, which indicates that the Ni 17 Y 2 phase was an effective reinforcement for the eutectic, which supplemented the matrix hardening due to increased solubility of Zr. Results suggest that ternary Ni-Y-Zr alloys hold significant promise for high temperature applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Materials Data on YNi2 by Materials Project

YNi2 is Cubic Laves structured and crystallizes in the cubic Fd-3m space group. The structure is three-dimensional. Y is bonded in a 12-coordinate geometry to twelve equivalent Ni atoms. All Y–Ni bond lengths are 2.97 Å. Ni is bonded to six equivalent Y and six equivalent Ni atoms to form a mixture of corner, edge, and face-sharing NiY6Ni6 cuboctahedra. All Ni–Ni bond lengths are 2.54 Å.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Materials Data on YNi5 by Materials Project

YNi5 crystallizes in the hexagonal P6/mmm space group. The structure is three-dimensional. Y is bonded in a 6-coordinate geometry to eighteen Ni atoms. There are six shorter (2.82 Å) and twelve longer (3.14 Å) Y–Ni bond lengths. There are two inequivalent Ni sites. In the first Ni site, Ni is bonded in a 12-coordinate geometry to three equivalent Y and six equivalent Ni atoms. All Ni–Ni bond lengths are 2.42 Å. In the second Ni site, Ni is bonded to four equivalent Y and eight Ni atoms to form a mixture of edge, corner, and face-sharing NiY4Ni8 cuboctahedra. All Ni–Ni bond lengths are 2.44 Å.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Materials Data on YNi3 by Materials Project

YNi3 crystallizes in the trigonal R-3m space group. The structure is three-dimensional. there are two inequivalent Y sites. In the first Y site, Y is bonded in a 12-coordinate geometry to twelve Ni atoms. There are a spread of Y–Ni bond distances ranging from 2.85–3.10 Å. In the second Y site, Y is bonded in a distorted hexagonal planar geometry to eighteen Ni atoms. There are six shorter (2.87 Å) and twelve longer (3.18 Å) Y–Ni bond lengths. There are three inequivalent Ni sites. In the first Ni site, Ni is bonded to five Y and seven Ni atoms to form a mixture of distorted corner, edge, and face-sharing NiY5Ni7 cuboctahedra. There are a spread of Ni–Ni bond distances ranging from 2.45–2.52 Å. In the second Ni site, Ni is bonded to six equivalent Y and six equivalent Ni atoms to form NiY6Ni6 cuboctahedra that share corners with twelve equivalent NiY5Ni7 cuboctahedra, edges with six equivalent NiY6Ni6 cuboctahedra, and faces with eighteen equivalent NiY5Ni7 cuboctahedra. In the third Ni site, Ni is bonded in a 12-coordinate geometry to three equivalent Y and six equivalent Ni atoms.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Materials Data on Y4Ni by Materials Project

Y4Ni is Iron carbide-like structured and crystallizes in the cubic Fd-3m space group. The structure is zero-dimensional and consists of eight Y4Ni clusters. Y is bonded in a single-bond geometry to one Ni atom. The Y–Ni bond length is 2.54 Å. Ni is bonded in a tetrahedral geometry to four equivalent Y atoms.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Materials Data on Y3Ni by Materials Project

Y3Ni is Cementite structured and crystallizes in the orthorhombic Pnma space group. The structure is two-dimensional and consists of two Y3Ni sheets oriented in the (0, 0, 1) direction. there are two inequivalent Y sites. In the first Y site, Y is bonded in a distorted water-like geometry to two equivalent Ni atoms. There are one shorter (2.78 Å) and one longer (2.84 Å) Y–Ni bond lengths. In the second Y site, Y is bonded in a distorted bent 150 degrees geometry to two equivalent Ni atoms. There are one shorter (2.75 Å) and one longer (2.80 Å) Y–Ni bond lengths. Ni is bonded in a 6-coordinate geometry to six Y atoms.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Materials Data on Y2Ni7 by Materials Project

Y2Ni7 crystallizes in the hexagonal P6_3/mmc space group. The structure is three-dimensional. there are two inequivalent Y sites. In the first Y site, Y is bonded in a 12-coordinate geometry to twelve Ni atoms. There are a spread of Y–Ni bond distances ranging from 2.81–3.15 Å. In the second Y site, Y is bonded in a 6-coordinate geometry to eighteen Ni atoms. There are a spread of Y–Ni bond distances ranging from 2.85–3.25 Å. There are five inequivalent Ni sites. In the first Ni site, Ni is bonded in a 12-coordinate geometry to three equivalent Y and six Ni atoms. There are three shorter (2.41 Å) and three longer (2.44 Å) Ni–Ni bond lengths. In the second Ni site, Ni is bonded to six equivalent Y and six equivalent Ni atoms to form NiY6Ni6 cuboctahedra that share corners with twelve equivalent NiY5Ni7 cuboctahedra, edges with six equivalent NiY6Ni6 cuboctahedra, and faces with eighteen equivalent NiY5Ni7 cuboctahedra. All Ni–Ni bond lengths are 2.52 Å. In the third Ni site, Ni is bonded to four equivalent Y and eight Ni atoms to form NiY4Ni8 cuboctahedra that share corners with sixteen NiY5Ni7 cuboctahedra, edges with ten NiY5Ni7 cuboctahedra, and faces with ten NiY4Ni8 cuboctahedra. There are a spread of Ni–Ni bond distances ranging from 2.43–2.48 Å. In the fourth Ni site, Ni is bonded to five Y and seven Ni atoms to form distorted NiY5Ni7 cuboctahedra that share corners with seventeen NiY6Ni6 cuboctahedra, edges with eight NiY4Ni8 cuboctahedra, and faces with fourteen NiY6Ni6 cuboctahedra. There are a spread of Ni–Ni bond distances ranging from 2.44–2.47 Å. In the fifth Ni site, Ni is bonded in a 12-coordinate geometry to three equivalent Y and six Ni atoms.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Materials Data on Y2Ni17 by Materials Project

Y2Ni17 crystallizes in the orthorhombic Cmcm space group. The structure is three-dimensional. there are two inequivalent Y sites. In the first Y site, Y is bonded in a 12-coordinate geometry to eighteen Ni atoms. There are a spread of Y–Ni bond distances ranging from 2.90–3.22 Å. In the second Y site, Y is bonded in a 2-coordinate geometry to twenty Ni atoms. There are a spread of Y–Ni bond distances ranging from 2.83–3.11 Å. There are eight inequivalent Ni sites. In the first Ni site, Ni is bonded in a 2-coordinate geometry to one Y and thirteen Ni atoms. There are a spread of Ni–Ni bond distances ranging from 2.36–2.69 Å. In the second Ni site, Ni is bonded to two equivalent Y and ten Ni atoms to form NiY2Ni10 cuboctahedra that share corners with fourteen NiY2Ni10 cuboctahedra, edges with six NiY3Ni9 cuboctahedra, and faces with ten NiY2Ni10 cuboctahedra. There are four shorter (2.38 Å) and four longer (2.40 Å) Ni–Ni bond lengths. In the third Ni site, Ni is bonded to two equivalent Y and ten Ni atoms to form NiY2Ni10 cuboctahedra that share corners with fourteen NiY2Ni10 cuboctahedra, edges with six NiY3Ni9 cuboctahedra, and faces with ten NiY2Ni10 cuboctahedra. There are four shorter (2.38 Å) and four longer (2.40 Å) Ni–Ni bond lengths. In the fourth Ni site, Ni is bonded in a 12-coordinate geometry to two Y and ten Ni atoms. There are a spread of Ni–Ni bond distances ranging from 2.35–2.51 Å. In the fifth Ni site, Ni is bonded in a 12-coordinate geometry to two Y and ten Ni atoms. There are a spread of Ni–Ni bond distances ranging from 2.35–2.51 Å. In the sixth Ni site, Ni is bonded in a 12-coordinate geometry to two Y and ten Ni atoms. There are two shorter (2.49 Å) and two longer (2.51 Å) Ni–Ni bond lengths. In the seventh Ni site, Ni is bonded to three Y and nine Ni atoms to form a mixture of distorted corner, edge, and face-sharing NiY3Ni9 cuboctahedra. Both Ni–Ni bond lengths are 2.39 Å. In the eighth Ni site, Ni is bonded to three Y and nine Ni atoms to form a mixture of distorted corner, edge, and face-sharing NiY3Ni9 cuboctahedra.

36 MATERIALS SCIENCE↗