Ni-based superalloys with enhanced oxidation resistance at high temperatures are crucial for next-generation gas turbine engines. A new polycrystalline Ni-based superalloy (C19) that combines improved microstructural stability with environmental resistance has been developed. Its oxidation resistance has been determined through measurements of the specific mass change and morphological evolution of the formed oxides following furnace exposures at 800 °C in air for up to 1000 hours; the results of which were benchmarked against Nimonic 105. C19 showed hybrid Type II/Type III behavior as a marginal Al2O3 former and performed similarly to established superalloys at 750 °C. The Wagner model for the transition from internal to external oxide formation predicted that C19 should form a continuous Al2O3 scale at higher temperatures. A pre-oxidation treatment at 1100 °C for 1 hour was, therefore, selected and shown to dramatically improve the oxidation resistance during subsequent exposure at 800 °C. Oxide cross-sectional analysis showed that C19 formed a continuous and protective Al2O3 scale after the pre-oxidation treatment, whereas Nimonic 105 retained discontinuous Al2O3 finger-like intrusions beneath a Cr2O3 overscale.

An assessment is made of the Wagner transition criteria for predicting the formation of a continuous Al2O3 scale in Ni-based superalloys. Predictions are compared with data from an experimental Ni-based superalloy as well as commercial superalloys for which published data are available. The methodology was generally successful in predicting the transition temperature of the commercial superalloys but underpredicted the transition temperature of the experimental superalloy by approximately 50–100 °C. The difference in the transition temperature of the experimental superalloy to form a continuous Al2O3 scale is primarily attributed to a complex oxide subscale that increased the internal volume fraction of oxide and led to reduced oxygen ingress. The sensitivity and limitations of the methodology are discussed, and recommendations are made to refine the methodology to facilitate the interpretation of oxidation behaviour in polycrystalline Ni-based superalloys.

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