Designing of novel microstructure and its impact on the improved service temperature mechanical performance of 2nd and 3rd generation advanced intermetallic TiAl alloys

Advanced lightweight TiAl based intermetallic systems, capable of surviving elevated temperatures, have been a topic of interest, considering their ever-increasing demands in aerospace industries. The optimization of solidification and processing methods stands as a pivotal factor in microstructural engineering for TiAl systems, aiming to attain desired mechanical properties. The present study focuses on two distinct alloy systems , a commercial grade 2nd generation, i.e., Ti–48Al–2Cr–2Nb (at. %), and a newly developed 3rd generation, i.e., Ti–45Al–2Cr-7.5Nb-0.2B (at. %) alloys. Interestingly, the variation in the solidification path, triggered by higher Nb content along with a minor amount of B, accounts for the substantial microstructural refinement for the 3rd generation TiAl alloy. Nevertheless, prominent segregation of Nb and Cr to the β 0 phase is observed in both the as-cast microstructure, which restricts the applicability of the alloys. Remarkably, a novel bilamellar-biglobular (BLBG) microstructure consisting of γ and α 2 phases in both lamellar and globular morphologies is achieved through heat treatment for both categories of alloy. Elevated temperature tensile testing depicts an exceptional strength-ductility combination for 3rd generation BLBG microstructure. Excellent twin-twin activity and twin-induced plasticity effect are observed to govern the deformation mechanism . Overall, the path of solidification, phase distribution, and its effect on the deformation mechanism are thoroughly analyzed, which is of particular interest from a design and application point of view. • Refinement in (α 2 + γ) colony size is noted for 3rd as compared to 2nd generation TiAl alloy. • Enrichment of β 0 phase with Nb and Cr is noted for both as-cast TiAl alloys. • β 0 .→ (α 2 ) g transformation forms bilamellar-biglobular (BLBG) microstructure upon heat treatment of TiAl alloys. • Twin induced plasticity (TWIP) effect is noted to dictate the deformation for this microstructure. • Excellent combination of elevated temperature strength and ductility is attained for heat treated TiAl-7.5Nb alloy.