Fundamental improvement of creep resistance of new-generation nano-oxide strengthened alloys via hot rotary swaging consolidation

ma e ials A icle Fundamen al Imp o emen o C eep Resis ance o New-Gene a ion Nano-Oxide S eng hened Alloys ia Ho Ro a y Swaging Consolida ion Jiˇ íS oboda 1,*, Lenka Kunˇcická1,2, Na ália Lup áko á1, Adam Weise 1and Pe Dymáˇcek 1 1Ins i u e o Physics o Ma e ials, Czech Academy o Sciences, Žižko a 22, 616 62 B no, Czech Republic; [email p o ec ed] (L.K.); [email p o ec ed] (N.L.); [email p o ec ed] (A.W.); [email p o ec ed] (P.D.) 2Facul y o Ma e ials Science and Technology, VŠB–Technical Uni e si y o Os a a, 17. Lis opadu 15, 708 33 Os a a, Czech Republic *Co espondence: [email p o ec ed] Recei ed: 22 Oc obe 2020; Accep ed: 16 No embe 2020; Published: 18 No embe 2020   Abs ac : New-gene a ion oxide dispe sion-s eng hened (ODS) alloys wi h a high olume ac ion o nano-oxides o 5% a e in ended o become he leading c eep- and oxida ion- esis an alloys o applica ions a 1100–1300 ◦ C. Ho consolida ion o mechanically alloyed powde s by in ensi e plas ic de o ma ion ollowed by hea ea men o he alloys a e he key aspec s o achie ing op c eep p ope ies, ypically ensu ed by a coa se-g ained mic os uc u e s eng hened wi h homogeneously dispe sed, e y s able y ium nano-oxides. The o a y swaging me hod p o es o be a ou able o ho consolida ion o he new-gene a ion ODS alloy p esen ed. Compa ed o specimens consolida ed by ho olling, consolida ion by ho o a y swaging p ede e mines he o ma ion o coa se g ains wi h a e y high aspec a io du ing subsequen seconda y ec ys alliza ion. Such a g ain mo phology inc eases he c eep s eng h o he new-gene a ion ODS alloy conside ably. Keywo ds: oxide dispe sion s eng hened (ODS) alloy; mechanical alloying; powde ho consolida ion; olling; o a y swaging 1. In oduc ion The de elopmen o ad anced ma e ials wi h excellen high- empe a u e c eep and oxida ion esis ance is one o he mos challenging goals o con empo a y ma e ial esea ch. Ni-based supe alloy single c ys als [ 1 ] applicable up o 1100 ◦ C, oxide dispe sion-s eng hened (ODS) e i ic alloys [ 2 ] applicable up o 1300 ◦ C, and ungs en hea y alloys (THAs) [ 3 ] applicable up o 1500 ◦ C, a e he op-le el me allic ma e ials wi h he bes c eep pe o mance. Ni-based supe alloy single c ys als a e ypically s eng hened by abou 70% olume ac ion o cuboidal γ´-p ecipi a es sepa a ed by hin channels o diso de ed γma ix [4,5]. Su icien con en o Al in he supe alloys ensu es hei excellen oxida ion esis ance. Howe e , cu ing he γ´ -phase by disloca ion, and ins abili y o he γ´ -p ecipi a es due o hei coa sening o a ing a empe a u es abo e 900 ◦ C, signi ican ly limi s long- e m applicabili y o Ni-based supe alloys in he empe a u e ange o 900–1100 ◦ C. The ODS alloys a e s eng hened by nano-dispe sion o e y s able Y-based oxides, ypically o 5–20 nm in size and 0.5% olume ac ion [ 6 , 7 ]. The e i ic ma ix o he ODS alloys also allows su icien alloying by Al (up o 10 w .%) ensu ing hei excellen oxida ion esis ance [ 8 ]. Bo h he e y good c eep and excellen oxida ion esis ance a e al eady co e ed by he exis ing ODS alloys o empe a u es up o 1300 ◦ C. The THAs p o i om e y high mel ing poin combined wi h solid solu ion and de o ma ion s eng hening [ 9 , 10 ]. The THAs a e, howe e , disquali ied by hei poo oxida ion esis ance and high speci ic mass. Thus, he mos p omising candida e o he op c eep- Ma e ials 2020,13, 5217; doi:10.3390/ma13225217 www.mdpi.com/jou nal/ma e ials Ma e ials 2020,13, 5217 2 o 11 and oxida ion- esis an alloys o long- e m applica ions in he empe a u e ange o 1100–1300 ◦ C s ems om he amily o he ODS alloys. ODS alloys a e ypically p oduced in wo s eps. Homogeneous powde consis ing o he ma ix and nano-sized Y 2 O 3 is p oduced by (i) mechanical alloying (MA) and (ii) consolida ed ia (a) ho ex usion (HE), (b) ho isos a ic p essing (HIP), (c) spa k plasma sin e ing, o hei combina ion[ 11 – 17 ]. Ve y ecen esea ch by he au ho s de o ed o he de elopmen o new-gene a ion ODS alloys wi h a high olume ac ion o oxides o abou 5% (being by one o de o magni ude highe han in classical ODS alloys) consolida ed ia ho olling [ 6 , 18 ] indica es ha he consolida ion condi ions a e impo an ac o s in luencing he inal c eep p ope ies o he alloys. Ne e heless, addi ional de o ma ion ( he momechanical) p ocessing o he ODS alloys is o en applied o ensu e elimina ion o po osi y and enhance hei pe o mance. The p ocessing can be pe o med ia nume ous con en ional, as well as uncon en ional, o ming me hods. Among he con en ional ones a e, o example, olling and o ging. Recen ly, Auge e al. [ 19 ] used ho -c oss olling o imp o e esis ance o 14YWT ODS alloy agains adia ion, and Zhang e al. [ 20 ] applied ho olling o inc ease he s eng h o Fe–9C -0.06C-1.5W-0.5Ti-0.18Si-0.35Y 2 O 3 ODS alloy (w .% a e used in all no a ions). Kuma e al. [ 21 ] s udied mechanical p ope ies o Fe-18C -2W-0.2Ti-xY 2 O 3 alloy consolida ed om mechanically alloyed powde by o ging. Zhou e al. [ 22 ] applied combina ions o o ging, ho olling, cold olling, and annealing o ODS310 alloy wi h Mo addi ion. Howe e , inhomogeneous bimodal g ain size dis ibu ion due o incomple e seconda y ec ys alliza ion and b i le c acking along he g ain bounda ies a e s ill issues o he ODS alloys [ 23 ]. Al hough coa se g ain mic os uc u e achie ed by ull seconda y ec ys alliza ion seems o be he key ac o o acqui ing excellen c eep s eng h, se e al ODS alloys in es iga ed in he a ailable li e a u e do no mee his equi emen . Ou expe imen s indica e ha he ul a ine g ained mic os uc u e o incomple e seconda y ec ys alliza ion in he ODS alloy cause he c eep s eng h o each only a ac ion o he c eep s eng h o he comple ely ec ys allized ones. Mo eo e , in se e al pape s, he mechanical p ope ies o e y expensi e ODS alloys a e s udied a loading condi ions, o which much be e and cheape subs i u es exis . I is highly desi able o limi he s udies o ODS alloys o condi ions, a which hei p ope ies a e eally excep ional. The o e all pe o mance o he ODS alloys can be imp o ed in wo ways, he i s o which is modi ica ion o hei chemical composi ion. The new-gene a ion ODS alloys a e p epa ed om powde s mechanically alloyed up o a deg ee o homogenei y a which he o e all amoun o oxygen o igina ing om he inpu y ia powde and oxidized su aces o he inpu me allic powde s is comple ely dissol ed and apped a de ec s, such as disloca ions and acancies. A e canning, he powde is ho olled unde op imized condi ions ensu ing he elimina ion o po osi y, as well as p o oking dynamic ec ys alliza ion esul ing in ul a- ine g ained (UFG) mic os uc u e. Nano-oxides o he ypical size o 5 nm, p ecipi a ed du ing he ho consolida ion, s abilize he UFG mic os uc u e up o e y high empe a u es o 1000–1100 ◦ C. I he ene gy s o ed du ing he ho olling eaches he c i ical alue, comple e seconda y ec ys alliza ion occu s du ing subsequen annealing a he empe a u es o 1200 ◦ C o se e al hou s [ 6 , 18 ]. As he esul , he inal mic os uc u e consis s o coa se g ains o he ypical size in he o de o 100 µ m s eng hened by homogeneous dispe sion o y ium nano-oxides o he ypical size o 20 nm [ 24 ]. Tensile es s pe o med a empe a u es exceeding 1000 ◦ C lead o a a he b i le in e g anula ac u e, which indica es ha high-angle g ain bounda ies a e he weakes link in he new-gene a ion ODS alloys due o hei limi ed cohesion s eng h. Howe e , o c eep expe imen s a he applied s ess o 40–60% o he s eng h measu ed by he ensile es , he cohesion o high-angle g ain bounda ies is su icien and he s a iona y c eep a e d ops o he alues o he o de o 10 −9 s −1 , as he dispe sion o nano-oxides e y e ec i ely supp esses he disloca ion c eep [ 25 ] and he ime o ac u e eaches hund eds o housands o hou s. Mo eo e , as he p ima y c eep s ain is a he small, ypically 0.1–0.2%, he new-gene a ion ODS alloys a e ad an ageous o design componen s equi ing long- e m igidi y a e y high empe a u es. The second way in which he pe o mance o he ODS alloys can be enhanced is he applica ion o op imized de o ma ion p ocessing ( he momechanical ea men ), which can ad an ageously Ma e ials 2020,13, 5217 3 o 11 be pe o med by uncon en ional o ming echniques and me hods o se e e plas ic de o ma ion (SPD). SPD me hods such as equal channel angula p essing (ECAP) [ 26 , 27 ] and ela ed me hods (non-ECAP [ 28 ], wis channel (mul i-) angula p essing [ 29 , 30 ], e c.), o high p essu e o sion (HPT) [ 31 ] a e a ou able o p ocessing o small olumes o ma e ials, while me hods such as accumula i e oll bonding (ARB) [ 32 , 33 ] and o a y swaging (RS) [ 34 ] a e ad an ageous o la ge bulk p oduc s. Ro a y swaging (RS) has been used o pe o m he momechanical p ocessing o a ious alloys, om b i le Mg-based compounds [ 35 , 36 ], h ough bio-applicable NiTi shape memo y alloys [ 37 , 38 ], Ti-based ma e ials wi h enhanced pe o mance [ 39 ], and me allic composi es [ 40 , 41 ], o FeCo magne ic compounds [ 42 ], and mode n s eels [ 43 ]. RS was also applied o he Eu o e ’97 ype o ODS a e consolida ion by HIP o HE [ 44 ]. RS seems o be e y p omising pa icula ly o consolida ion o canned ODS powde s due o i s inc emen al cha ac e , p e ailing comp essi e s ess s a e, and high imposed shea s ains [ 45 – 47 ]. Compa ed o HE, RS is a s anda d indus ial echnology allowing ela i ely easy and cheap p oduc ion o solid, hollow, o p o iled ba s wi hin a wide ange o diame e s. The p esen s udy in oduces he Fe-10Al-3Y 2 O 3 -1Ti new-gene a ion ODS alloy consolida ed om a mechanically alloyed powde by wo me hods o in ensi e plas ic de o ma ion: (i) ho olling, and (ii) ho RS. To he bes o he au ho s’ knowledge, his is he e y i s expe imen in which ho RS has been u ilized o ODS alloy consolida ion. To demons a e he a ou able e ec s o RS, mic os uc u es and c eep p ope ies o olled and swaged samples a e compa ed and he esul s o expe imen s a e discussed in de ail. 2. Ma e ials and Me hods Chemically homogeneous Fe-10Al-3Y 2 O 3 -1Ti powde was p epa ed om Fe, Al, Y 2 O 3 , and Ti powde s o 99.9% pu i y by MA using a sel -made ball mill. A acuum- igh milling con aine wi h he olume o 22 dm 3 and diame e o 400 mm made om low alloyed s eel was illed wi h 100 Fe-1C -1C bea ing balls o 40 mm diame e (al oge he 25 kg). The o al amoun o 1 kg o he powde was mechanically alloyed by o a ion o he milling con aine along he ho izon al axis (70 pm). A e a su icien ly long MA ( wo weeks) in acuum, he powde p ope ies became sa u a ed and he powde pa icles consis ed o a homogeneous solid solu ion wi h a huge densi y o de ec s, like disloca ions and acancies (see [ 6 ] o mo e de ails). The a he wide size dis ibu ion (be ween 2 o 200 µm) o he cold compac ed powde can be de e mined om Figu e 1. I is e y complica ed o de e mine he mean pa icle size due o e y wide size dis ibu ion. Mo eo e , he powde in ol es a huge densi y o de ec s and he g ains and hei g ain bounda ies a e no well de ined. The measu ed con en o C (0.05%) in he MA powde indica es ha abou 5% o he milling balls is in oduced in o he MA powde by he ab asion o milling balls and hus he MA powde con ains also 0.05% o C. The in luence o milling media on he mic os uc u e and mechanical p ope ies o mechanically milled and sin e ed aluminium was analyzed e.g. in [48]. Figu e 1. Me allog aphic sec ion o he mechanically alloyed powde o he new-gene a ion ODS alloy. Ma e ials 2020,13, 5217 4 o 11 The MA powde was ho consolida ed by using wo echniques: (i) olling and (ii) RS. The olling cylinde s o diame e 75 mm in he mill o a ed a he speed o 65 pm. The o a y swaging machine by he HMP company allowed s epwise educ ion o axisymme ic ba s. Fou swaging dies pe o med high- equency adial mo emen s wi h sho s okes and applied comp essi e o ce o he inse ed wo kpiece. The o ming p ocess ook place in many small p ocessing s eps and, he e o e, RS can be desc ibed as an inc emen al o ming p ocess. In eed swaging wi h lee ing clamping o he swaged sample was used. The en i e swaging was pe o med a he empe a u e o 950 ◦ C wi h no lub ica ion. The specimens we e hea ed and kep 5 min a he equi ed empe a u e in he a mosphe ic u nace be o e each consolida ion s ep. The con aine s o ho olling and ho RS made om s ainless s eel ubes we e illed wi h he mechanically alloyed powde , e acua ed, and sealed by welding. The olling con aine was ho olled in h ee s eps om he ini ial diame e o 20 mm o he inal hickness o he shee o 3.2 mm a 960 ◦ C. The swaging con aine was ho o a y swaged om he ini ial diame e o 50 mm o he inal diame e o 15 mm a he same empe a u e, o p o ide simila ho consolida ion condi ions. The schema ic depic ion o he olling and swaging p ocesses o he new-gene a ion ODS alloy, including geome ies o he canned semi-p oduc s and de ini ion o he u he desc ibed di ec ions, is shown in Figu e 2. A e s ipping om he con aine s, he consolida ed new-gene a ion ODS alloys we e seconda ily ec ys allized by annealing in a acuum u nace a 1200 ◦C o 4 h. Figu e 2. Rolling and swaging geome ies used o consolida ion o new-gene a ion oxide dispe sion-s eng hened (ODS) alloys. The s udy deals wi h wo se s o specimens o he seconda y ec ys allized new-gene a ion ODS alloy. Fla specimens wi h he gauge leng h o 25 mm and c oss sec ion o 2.5 mm × 3.5 mm cu by p ecise wa e je and g inded om he olled shee s a e deno ed as Specimens I, while ci cula specimens wi h he gauge leng h o 25 mm and diame e o 6 mm p oduced om he swaged ods a e deno ed as Specimens II. The ensile and c eep es s we e pe o med using Zwick/Roell—Messphysik KAPPA LA (Fü s en eld, Aus ia) sp ing 20 kN c eep es sys em equipped by MAYTEC u nace (Singen, Ge many) wi h he wo king empe a u es up o 1400 ◦ C. One specimen o a ensile es a cons an a e 10 −6 s −1 and ou , espec i ely i e, specimens we e used o he c eep es s o Specimens I and II (i.e., one specimen o each applied s ess). The mic os uc u es we e obse ed using a scanning elec on mic oscope (SEM) Tescan Ly a 3 XMU FEG/SEMxFIB (Tescan, B no, Czech Republic) equipped wi h X-Max80 EDS (ene gy-dispe si e X- ay) de ec o o X- ay mic oanalysis and EBSD (elec on backsca e di ac ion) de ec o wi h Az ec con ol sys em (Ox o d Ins umen s, Abingdon, UK). 3. Mechanical Tes ing The ensile es s pe o med a he empe a u e o 1100 ◦ C and s ain a e o 10 −6 s −1 showed he s eng h o 75 MPa and duc ili y o 1.1% o Specimens I, and s eng h o 115 MPa and duc ili y o 1.2% o Specimens II. The a he small duc ili y and he pu ely in e g anula ac u e indica ed ha he g ain bounda y cohesion s eng h was he weakes link in he specimens. This weakes link, howe e , did no necessa ily play an impo an ole in he c eep expe imen s a he applied s ess signi ican ly below he measu ed ensile s eng h. Ma e ials 2020,13, 5217 5 o 11 The esul s o c eep es s pe o med a 1100 ◦ C a e summa ized in Figu e 3. To ge an idea abou he c eep p ope ies o he new-gene a ion ODS alloy, he esul s a e compa ed wi h he da a shee o he op comme cial ODS alloy, MA 956 [ 49 ] (only imes o up u e a e a ailable). Figu e 3a ob iously shows ha he s ess exponen o ime o up u e is much highe o Specimens II compa ed o Specimens I. This can be a ibu ed o he signi ican ly inc eased c eep duc ili y o Specimens II a low s esses. The s ess exponen s o minimum c eep a e shown in Figu e 3b a e simila o bo h Specimens I and II. I is e iden om he c eep es s (see Figu e 3a) ha he s eng h o Specimens II is signi ican ly (by a ac o o abou 1.5 o 2) highe han ha o Specimens I and he minimum c eep a e is lowe by mo e han wo o de s o magni ude (see Figu e 3b). To explain hese ac s, SEM analysis was u he pe o med. Figu e 3. Compa ison o ( a ) ime o up u e; ( b ) minimum c eep a e o Specimens I and II. In e up ed c eep es o Specimens II a 60 MPa is used o de e mine he minimum c eep a e. 4. Mic os uc u e Cha ac e iza ion The mic os uc u es acqui ed by SEM (back-sca e ed elec on analysis) om cen al pa s o he samples a e ho olling and ho RS a e compa ed in Figu e 4a,b, espec i ely. The g ain mic os uc u e o he olled specimen (Figu e 4a) is e y ine (100 nm); he g ains a e mo e o less equiaxed (aspec a io nea o 1) and exhibi a a he na ow size dis ibu ion. By con as , he g ain mic os uc u e a e RS (Figu e 3b) is signi ican ly coa se ( he wid h o g ains 200 nm) and conside ably elonga ed (aspec a io 2.2) in he di ec ion o he swaging axis (ho izon al di ec ion). Figu e 4. Compa ison o mic os uc u es p epa ed by ( a ) ho olling in RollDxND plane; ( b ) ho o a y swaging (RS) in SDxRadD plane. Ma e ials 2020,13, 5217 6 o 11 The elec on backsca e di ac ion (EBSD) analyses o g ain mic os uc u es o Specimens I and II a e seconda y ec ys alliza ion, which led o a d as ic inc ease in he g ain size by nea ly ou o de s o magni ude, a e compa ed in Figu e 5. The shapes o he g ains in Specimens I sligh ly esemble pancakes in he olling plane (ho izon al di ec ion in Figu e 5a), he g ains in Specimens II exhibi shapes wi h a high aspec a io along he swaging axis (ho izon al di ec ion in Figu e 5b). No signi ican ex u e o ma ion is de ec ed om he in e se pole igu es (see Figu e 5c,d). Figu e 5. Compa ison o g ain mic os uc u es a e seconda y ec ys alliza ion ( a ) Specimens I in RollDxND plane; ( b ) Specimens II in SDxRadD plane, scanning elec on mic oscopy (SEM)–elec on backsca e di ac ion (EBSD) in e se pole igu es o ( c ) Specimens I; ( d ) Specimens II. Indi idual di ec ions a e de ined in Figu e 2. The mic os uc u es ea u ing dispe sions o nano-oxides inside he seconda y ec ys allized g ains o Specimens I and II a e compa ed in Figu e 6, which show ha he oxide dispe sion in Specimens I is signi ican ly ine and mo e homogeneous han in Specimens II. The eason o he di e ence can be ound in he compa ison o g ain mic os uc u es a e ho consolida ion p esen ed in Figu e 4. The g ains a e ho olling a e e y ine (o he o de o 100 nm) and he size o he oxides ( ypically 5 nm, see Figu e 1b in e e ence [ 50 ]) is below he esolu ion o SEM ( ypically obse ed by ansmission elec on mic oscopy). The oxides a he g ain bounda ies coa sen as e han hose wi hin he g ain in e io s du ing annealing and hus he mo phology o he ho - olled mic os uc u e (see Figu e 4a) is imp in ed in he oxide dispe sion a e seconda y ec ys alliza ion. Only he nano-oxides o iginally si ua ed a he g ain bounda ies o he UFG mic os uc u e emain as hey consume he nano-oxides om in e io s o ul a ine g ains du ing annealing. The g ain mic os uc u e a e ho RS is much coa se (500–1000 nm) han ha a e ho olling and he g ains a e conside ably elonga ed in he di ec ion o swaging axis, see Figu e 4b. Mo eo e , he swaged s uc u e al eady con ains some po ion o ela i ely coa se nano-oxides (20–50 nm). By hese easons, he nano-oxide dispe sion in Specimens II, e lec ing he ho -swaged g ain mic os uc u e, is coa se and less homogeneous and ea u es a wide size dis ibu ion. As he nano-oxides a e again si ua ed p edominan ly in loca ions o he o iginal g ain bounda ies a e RS, he nano-oxides o m chains pa allel o he swaging axis a he me allog aphic sec ion in Figu e 6b. Ma e ials 2020,13, 5217 7 o 11 Figu e 6. Compa ison o mic os uc u es o nano-oxide dispe sion wi hin g ains o ( a ) Specimens I (b) Specimens II (SEM—backsca e ed elec ons). 5. Discussion The o ma ion o g ains wi h high aspec a io in Specimens II by seconda y ec ys alliza ion (Figu e 5b) can be explained as ollows. Due o he Zene pinning, he g ain bounda y o he seconda y ec ys allizing g ain mig a es easily ac oss he zones o low-densi y o nano-oxides and emains ancho ed in he zones wi h a e y high densi y o nano-oxides. As he nano-oxides a e concen a ed p edominan ly a he loca ions o he o iginal g ain bounda ies a e RS, i.e., p edominan ly a su aces pa allel o he swaging axis, he e ec i e mobili y is signi ican ly lowe o he g ain bounda ies pa allel o he swaging axis han o hose no mal o he swaging axis. Du ing he subsequen seconda y ec ys alliza ion, he g ow h a e o he g ains aligned wi h he swaging axis is highe han he g ow h a e o he g ains aligned wi h he no mal o he swaging axis, which explains he o ma ion o g ains wi h high aspec a io pa allel o he swaging axis a e seconda y ec ys alliza ion (see Figu e 5b). When uniaxial s ess is applied a e y high empe a u es, edis ibu ion o s ess wi hin he specimen occu s apidly and a ce ain pa o he applied s ess is equilib a ed by shea s esses a he g ain bounda ies pa allel o he di ec ion o he applied s ess. The highe ac ion o g ain bounda ies pa allel o he loading axis exis s in he specimen, and mo e loading is ans e ed by his edis ibu ion e ec . As he ac ion o g ain bounda ies pa allel o he loading axis is signi ican ly highe in Specimens II han in Specimens I, and he cohesi e s eng h o he g ain bounda ies no mal o he applied s ess is he gi en limi ing ac o , he s eng h o Specimens II is conside ably highe han o ha o Specimens I. The g ain geome y wi h high aspec a io and nano-oxide dis ibu ion pa e n leads o aniso opy in he mechanical p ope ies and de e mines high ensile s eng h along he swaging axis. This may be ad an ageous o speci ic uniaxially loaded componen s, such as pull ods and g ips in es ing machines wo king a e y high empe a u es. Mo eo e , excellen oxida ion esis ance o he Fe-10Al-3Y 2 O 3 -1Ti is gua an eed by he high con en o Al o ming a p o ec i e compac alumina su ace ilm by eac ion wi h he ai . The p o ec i e ilm may also p ohibi eac ion o pull ods and g ips wi h es ed specimens. Special ca e mus be aken o a oid signi ican inhomogenei ies in he g ain size, as his may cause seconda y c acking o delamina ion, as desc ibed in [ 51 , 52 ]. Thus, comple e seconda y ec ys alliza ion is equi ed op oceedin hesamples. The espec i emodel o he ea men o dynamic ec ys alliza ion du ing ho consolida ion ollowed by seconda y ec ys alliza ion is p esen ed in [ 50 ]. The model clea ly shows ha only selec ed ho consolida ion condi ions om he p ocessing window may lead o comple e seconda y ec ys alliza ion du ing subsequen annealing, which is he case o in his s udy. Conce ning he mechanical p ope ies a 1100 ◦ C, he in luence o he consolida ion me hod is subs an ial. Bo h he ensile es s eng h and c eep s eng h a e by a ac o o abou 1.5 o 2 highe o Specimens II han o Specimens I. This is despi e he ac ha he nano-oxide dispe sion in Specimens Ma e ials 2020,13, 5217 8 o 11 I is mo e egula han ha in Specimens II, see Figu e 6. Summa izing based on he con incing esul s, he g ains in bo h Specimens I and II a e su icien ly s eng hened by he dispe sion o nano-oxides and he mechanical p ope ies a 1100 ◦ C a e, o he gi en cohesion o he g ain bounda ies, de e mined p edominan ly by he g ain geome y. Today, ODS alloys a e no p oduced on he comme cial basis any mo e, which is mos p obably due o hei a he complica ed p ocessing esul ing in a e y high p ice and, consequen ly, low ma ke demand. The p ocessing o new-gene a ion ODS alloys is much less complica ed when u ilizing s anda d indus ial p ocedu es such as olling o RS o ho consolida ion. The use o he sel -made a i o is also e y simple and cheap and i allows easy up-scaling. I he chemical composi ion and ho -consolida ion condi ions a e op imized o ensu e he comple e seconda y ec ys alliza ion as a s anda d, he powe o p ize a io o he new-gene a ion ODS alloys will be signi ican ly highe han ha o he ecen ODS alloys and comme cial in e es in ODS alloys enewed. 6. Conclusions The conclusions can be summa ized as ollows: • Two ba ches o he Fe-10Al-3Y 2 O 3 -1Ti new-gene a ion ODS alloys a e p epa ed by ho consolida ion o mechanically alloyed powde using (i) olling and (ii) o a y swaging. • Seconda y ec ys alliza ion o he ho o a y swaging consolida ed specimens ea u ing ul a- ine-g ained mic os uc u e leads o a he coa se g ains signi ican ly elonga ed in he di ec ion o swaging axis. • Al hough he mic os uc u e o nano-oxides in he seconda y ec ys allized g ains o he ODS alloy consolida ed by ho olling is signi ican ly mo e egula and ine han ha o he ODS alloy consolida ed by ho o a y swaging, he s eng h o he la e a 1100 ◦ C is by a ac o o 1.5 o 2 highe han ha o he i s one. • The c eep s eng h o he p esen new-gene a ion o ODS alloy a 1100 ◦ C is p edominan ly de e mined by he mo phology o g ain bounda ies being he weakes link due o hei limi ed cohesi e s eng h. • The c eep s eng h a 1100 ◦ C o he new-gene a ion ODS alloys consolida ed by ho o a y swaging exceeds ha o op comme cial ODS alloy by mo e han 30%. • The ho consolida ion o he ODS powde ia o a y swaging compa ed o olling is p o en ad an ageous o p oduc ion o he new-gene a ion high-s eng h ODS alloys o applica ion a empe a u es 1100–1300 ◦C. 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