Tungsten-based self-passivating metal alloys with reduced thermo-oxidation (SMART), which using Cr or Si as oxidation-resistant elements, have exhibited great potential for oxidation resistance application at high temperature compared with pure W. In this work, aluminum (Al) was added to W
Cr SMART systems to further improve the oxidation resistance, and the novel W-17.8Cr-6.4Al alloys were successfully developed using spark plasma sintering (SPS) technique. The influence of sintering pressure and temperature on the densification process was systematically investigated, and the oxidation behaviors were studied at 800 °C and 1000 °C. The sintering curves exhibit that there is the liquidation of Al above around 630 °C, and the rapid densification of W-Cr-Al alloys starts above 923–950 °C. The intermetallic compounds of (WCr)Al12 and (WCr)Al4 are generated when sintered at 650 °C and 700 °C, respectively. When sintered above 1000 °C, W-Cr-Al alloys mainly consist of two BCC phases of W-Cr-Al solution. Dense bulk W-Cr-Al alloys, with a density of around 11.6 g/cm3, could be manufactured by sintering above 1200 °C at 20 MPa for 15 min. At the end of oxidation, the oxides formed at 800 °C mainly consist of WO3, Cr2WO6 and Al2W3O12, while WO3 disappears at 1000 °C due to the volatilization of WO3 and the reaction with Cr2O3. In addition, no obvious variation trend of mass gain is observed when oxidized at 800 °C compared with pure W, while a double parabolic trend of mass gain is found during oxidization at 1000 °C. The parabolic oxidation parameter, , is around (7–8) × 10−5 mg2/(cm4min) and (4–5) × 10−4 mg2/(cm4min), respectively. Compared to the linear oxidation behavior of pure W, W-Cr-Al alloys exhibit its potential for oxidation resistance application at high temperature.
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