KIT's revolutionary alloy: the future of aviation is heat-resistant!

KIT's revolutionary alloy: the future of aviation is heat-resistant!

A research team from the Karlsruhe Institute of Technology (KIT) has developed a novel refractory metal alloy that offers promising properties for applications at extreme temperatures. The alloy, which consists of chromium, molybdenum and silicon, is malleable at room temperature and remains stable up to around 2,000 degrees Celsius. Oxidation resistance is also one of the outstanding properties of this new class of materials. This discovery in the scientific journal Nature was published, marks an important advance in basic research. High-temperature-resistant materials are particularly important for use in aircraft engines, gas turbines and X-ray machines.

Previous refractory metals are brittle at room temperature and oxidize at temperatures between 600 and 700 degrees Celsius. Nickel superalloys are currently in use that can only withstand temperature fluctuations of up to a maximum of 1,100 degrees Celsius. KIT's new alloy, on the other hand, could make it possible to manufacture components for temperatures above 1,100 degrees Celsius, which would enable the operating temperatures in turbines to be increased in order to reduce fuel consumption by around 5%. This development is not only technically relevant, but also contributes to reducing CO₂ emissions in aviation and stationary gas turbines.

Challenges and potential for improvement

Despite advances in high-temperature alloys, there are still challenges to be overcome. A key problem is oxidation resistance, particularly at temperatures between 600 °C and 800 °C, where there is a risk of “pesting”. However, above 1,000 °C, a protective borosilicate layer forms that protects the material from oxidation. Research on refractory metal-based Mo-Si-B alloys shows that they represent promising alternatives to nickel-based superalloys, particularly when it comes to meeting aerospace industry requirements for mechanical properties and oxidation resistance, such as Research Saxony-Anhalt determines.

In order to further improve the performance of these new alloys, comprehensive development and optimization processes are necessary. This includes establishing a powder metallurgical manufacturing route that uses mechanical alloying as a basis. Current projects focus on the development of Mo-40V-9Si-8B materials with an appropriate coating to verify the mechanical properties and oxidation resistance of these materials.

Future prospects

Another goal of the research is to develop metallic alloys that can withstand extreme conditions, including high temperatures, high pressures and corrosive media. Cr-based alloys, which have advantageous physical and mechanical properties, should be taken into account. The use of labyrinth honeycomb seals to seal between the rotor and stator is also an approach to minimize airflow leakage and increase the efficiency of aircraft turbines, which in turn helps reduce carbon dioxide emissions, such as Metals University of Bayreuth describes.

Overall, the development of these new refractory metal alloys represents a significant advance that has both industrial and environmental implications. In the long term, these materials could play a crucial role in aerospace and other industries where high temperatures and demanding conditions exist.