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<p>This work develops a physics-based reaction–diffusion model for the oxidation of nickel-based superalloys that explicitly couples oxygen transport, aluminum consumption, and oxidation-induced swelling within a unified formulation. The model captures α-alumina scale growth, substrate aluminum depletion, and the effect of swelling-driven deformation on diffusion. Model predictions show good agreement with experimental data and highlight the role of aluminum-rich bond coats in limiting depletion by serving as aluminum reservoirs. The novelty of this work lies in a unified reaction–diffusion framework that simultaneously incorporates oxidation-induced swelling and aluminum depletion, enabling mechanistic predictions of long-term oxidation behavior. This formulation provides a foundation for future extensions to stress-coupled or three-dimensional analyses relevant to high-temperature component life assessment.</p>

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Physics-Based Diffusion–Reaction Oxidation Model for Coated Ni-Based Superalloys

  • 期刊论文

  • 发表日期：

    2026年7月20日

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  • A. Staroselsky,
  • B. N. Cassenti

摘要

This work develops a physics-based reaction–diffusion model for the oxidation of nickel-based superalloys that explicitly couples oxygen transport, aluminum consumption, and oxidation-induced swelling within a unified formulation. The model captures α-alumina scale growth, substrate aluminum depletion, and the effect of swelling-driven deformation on diffusion. Model predictions show good agreement with experimental data and highlight the role of aluminum-rich bond coats in limiting depletion by serving as aluminum reservoirs. The novelty of this work lies in a unified reaction–diffusion framework that simultaneously incorporates oxidation-induced swelling and aluminum depletion, enabling mechanistic predictions of long-term oxidation behavior. This formulation provides a foundation for future extensions to stress-coupled or three-dimensional analyses relevant to high-temperature component life assessment.