Cost-Effective Optimization of High-Temperature Performance in Oxide Dispersion Strengthened Ni-Based Alloys through NbSi Powder Integration and Dual-Phase Composites

Abstract Oxide dispersion strengthened (ODS) Nickel-based superalloys exhibit remarkable thermal stability and mechanical performance at temperatures exceeding 1100 °C, making them indispensable for critical components such as aircraft engines and gas turbine blades. In this study, NbSi alloys were introduced into ODS Ni-based alloys at varying concentrations (10-40 wt.%) to optimize their thermal and mechanical characteristics. The influence of microstructural changes on high-temperature properties was evaluated through Vickers hardness and Gleeble tests. The alloy mixture with 25 wt.% NbSi alloy content exhibited high-temperature Vickers hardness of 363.4 and 343.7 HV at 800 and 900 °C, respectively, and a maximum high-temperature compressive strength of 567 MPa. These values surpass those of conventional ODS Ni-based alloys and demonstrate the synergistic effect of dual-phase shell and thermally stable phases. Thus, the NbSi-mixed ODS Ni-based alloys are promising candidates for advanced high-temperature structural applications, particularly in aerospace and energy sectors.