Optimizing aluminum content in DZ409 alloy: Analysis of microstructural and mechanical properties for high-temperature applications

This research investigates the microstructural characteristics of DZ409 alloys. It explores how varying aluminum (Al) contents by weight (3.42–4.22 wt. %) influenced carbide size, volume fraction, and phase distribution in both as-cast and heat-treated states. The results of this study revealed that the size of Metallic Carbide (MC) carbides exhibited a non-linear trend, initially increasing and subsequently decreasing with a higher Al content. Similar trends were observed in the size and area fraction of the γ/γ′ eutectic phase. Post-heat treatment analysis demonstrated that increased Al content significantly impacted interdendritic and dendritic stem phases, leading to augmented volume and size. The mechanical properties of the heat treatment associated with the DZ409 alloy were also analyzed, which showed some notable enhancement in the tensile strength and yield strength. The stress life analysis at 980 °C/MPa also indicates the increased Al content on alloy performance. The findings highlight the pivotal role of Al in terms of improved microstructural attributes and mechanical properties of DZ409 alloys. To conclude, optimizing the Al content can potentially improve the functionality and durability of DZ409 alloy, making them particularly suitable for high-temperature environments, such as gas turbine applications.