Effects of Aluminization Via Thermo-Chemical Diffusion on the Wear Behavior of Structural Materials for High-Temperature Gas-Cooled Reactors

We explore the effects of thermo-chemical aluminization on wear resistance of candidate alloys Incoloy 800HT and Inconel 617 for high-temperature gas-cooled reactor (HTGR) components. Aluminized samples were conditioned for 22 days in a once-through helium loop to simulate oxidizing conditions of HTGRs. The tribological performance of unconditioned and conditioned samples was tested using pin-on-disk tribometer in an air environment at 750 °C for 800HT and 900 °C for 617. Aluminized 800HT exhibited superior wear resistance compared to that of the as-received 800HT due to harder Fe-Al intermetallic compounds that formed at the surface of the alloy. Aluminized 617 exhibited wear resistance superior to that of the as-received 617 at higher loads but inferior resistance at lower loads. Conditioned 800HT as well as aluminized and then conditioned 800HT exhibited negligible wear when the protective oxide remained intact during tribotesting. When the oxide wore through, aluminized and then conditioned 800HT exhibited superior wear resistance compared to that of conditioned 800HT due to the increased hardness of intermetallic zones. Aluminized and then conditioned 617 exhibited inferior wear resistance compared to that of conditioned 617 due to significant ceramic wear of the aluminum oxide. Connections between surface hardness, chemical composition, initial friction coefficients, and wear resistance are established.