In order to promote the development of ultra-supercritical technology, the optimum composition design of three new alumina-forming austenitic heat-resistant steels, based on Fe–22Cr–25Ni (wt. %), with low cost and excellent performance, and used for 700 °C ultra-supercritical unit was carried out using Thermo-Calc software. A comparison of the mechanical properties presented that with increasing Al content, the plasticity of the system was further improved. Based on the composition system, a systematic investigation regarding the structure stability, thermodynamic properties, and mechanical properties of these new steels was carried out to reveal possible strengthening and toughening mechanisms by employing the first-principles method. Calculation results showed that when Al existed in the Fe–Cr–Ni alloy system as a solid solution, the new structures were stable, especially under high temperature. The solution of Al and Al + Si could increase the value of B/G, namely improving the plasticity of the system, particularly in case of alloying with Al + Si. The inclusion of Si in the Fe–Cr–Ni–Al system was conducive to further improving the plasticity without affecting the strength, which provided references for the subsequent optimum composition design and performance regulation of alumina-forming austenitic heat-resistant steels.
Sanicro 25 austenitic heat-resistant steel is expected to be used in superheaters and reheaters for ultra-supercritical power plants above 600 °C due to its excellent structural stability and high temperature mechanical properties. In this paper, the effects of Co and W on the structural stability, thermodynamic stability and mechanical properties of Sanicro 25 steel are analyzed by calculating the formation energy, binding energy, Gibbs free energy, elastic constant, Peierls stress and generalized stacking fault energy (GSFE) with first-principles calculation method. By calculating the formation energy, binding energy and Gibbs free energy, it concludes that alloying elements Co and W in Sanicro 25 steel can improve the structural stability and thermodynamic stability. It indicates that W and a small amount of Co can improve the plasticity and ductility of Sanicro 25 steel by calculating the bulk modulus (B), shear modulus (G), Young’s modulus (E), the B/G ratio, Poisson’s ratio and Peierls stress. It is found that when Co and W are far from the stacking fault region, it will promote the formation of partial dislocations and twins in the system, thereby improving its plastic deformation ability and mechanical properties.
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