Composition effect on elastic properties of model NiCo-based superalloys

NiCo-based superalloys exhibit higher strength and creep resistance over conventional superalloys.Compositional effects on elastic properties of the γ and γ' phases in newly-developed NiCo-based superalloys were investigated by first-principles calculation combined with special quasi-random structures.The lattice constant,bulk modulus,and elastic constants vary linearly with the Co concentration in the NiCo solution.In the selected(Ni,Co)3(Al,W)and(Ni,Co)3(Al,Ti)model γ' phase,the lattice constant,and bulk modulus show a linear trend with alloying element concentrations.The addition of Co,Ti,and W can regulate lattice mismatch and increase the bulk modulus,simultaneously.W-addition shows excellent performance in strengthening the elastic properties in the γ' phase.Systems become unstable with higher W and Ni contents,e.g.,(Ni0.75Co0.25)3(Al0.25 W0.75),and become brittle with higher W and Co addition,e.g.,Co3(Al0.25 W0.75).Furthermore,Co,Ti,and W can increase the elastic constants on the whole,and such high elastic constants always correspond to a high elastic modulus.The anisotropy index always corresponds to the nature of Young's modulus in a specific direction.

Laser engineered net shaping of Co-based superalloys

Laser engineered net shaping(LENS) process was investigated using Co-based superalloy powder with a high power continuous wave CO2 laser. Thin wall part with smooth surface was obtained by LENS of layer-by-layer deposition of the powder materials. This thin wall sample was tested for metallographic examinations, micro-hardness, X-ray diffraction and mechanical property test. Microstructural results show that the layers possess rapid solidification microstructural feature, fine dendritic crystal and M7C3-type carbides (essentially chromium-rich carbide) dispersed in theγ(Co,Cr) phase matrix. Dendrite spacing as well as the solidification mode can be controlled through control process parameters. In addition, this microstructural feature of the as-formed Co-base sample leads to an evident hardening and a superior tensile strength and toughness.

Hot Compression Behavior and Tensile Property of a Novel Ni-Co-Based Superalloy Prepared by Electron Beam Smelting Layered Solidification Technology

The hot compression behavior and tensile strength after compression of a new Ni-Co-based superalloy produced using electron beam smelting layered(EBSL)solidification technology were investigated.Isothermal compression tests were performed at temperatures of 1120℃and 1150℃,with strain rates of 1 s^(-1) and 0.01 s^(-1),reaching a true strain of 0.51.Tensile strength was evaluated at room temperature.The results revealed that this EBSL technology accelerates dynamic recrystallization(DRX),without compromising the strength of alloy.A significant correlation between the volume fraction of DRX and the strain rate was observed,with higher fractions at lower strain rates,leading to higher tensile strength.Additionally,at the same strain rate,the specimens compressed at 1120℃exhibited higher tensile strength due to undissolvedγ′precipitates.After solution and aging heat treatment,the alloy maintained high tensile strength.The results suggested that the EBSL Ni-Co-based superalloy offers excellent prospects for practical applications.

Recrystallization Behavior of the New Ni-Co-Based Superalloy with Fusion Structure Produced by Electron Beam Smelting Layered Solidification Technology

The new Ni-Co-based superalloy featuring a"fusion structure"was produced utilizing electron beam smelting layered solidification technology(EBSL).Experimental examination of hot compression deformation with varied settings for EBSL and conventional duplex process melting Ni-Co superalloys was performed.As per the study,EBSL-Ni-Co superalloys exhibited enhanced recrystallization susceptibility during hot deformation.Furthermore,elevating deformation temperature,lowering strain rate,and augmenting strain collectively contribute to enlarging the volume fraction of dynamically recrystallized grains.Aberrant growth of grains occurred when the deformation temperature equaledγ′sub-solvus temperature and the strain rate was slower.Moreover,exceeding theγ′solvus temperature during deformation significantly increases the particle size of dynamic recrystallization(DRX)grains.Theγ′phase can effectively modulate the DRX grain size through the pegging effect.Additionally,it was revealed that the presence of the fusion structure aids in the generation of continuous dynamic recrystallization,discontinuous dynamic recrystallization,and twinning-induced dynamic recrystallization while the alloy undergoes hot deformation.This mechanism promotes DRX granule formation and permits complete recrystallization.Ultimately,the fusion structure was identified as playing a catalytic role in the dynamic recrystallization process of the new Ni-Co superalloy.

Selective Laser Melting of Carbon-Free Mar-M509 Co-Based Superalloy:Microstructure,Micro-Cracks,and Mechanical Anisotropy

In this work,the microstructural evolution,micro-crack formation,and mechanical anisotropy of the selective laser melted(SLM)carbon-free Mar-M509 Co-based superalloy were systematically studied under different linear energy densities(LED).Observation shows that the SLM Mar-M509 superalloy possesses a fully dense structure,whereas some microcracks exist along the building direction.The electron backscatter diffraction results reveal that dominant columnar grains tend to elongate along the building direction parallel to the XZ plane.Meanwhile,both a<001>near fiber texture and a{100}<001>near sheet texture are observed in different specimens.For the specimen with fiber texture,a high misorientation angle exists among different columnar grains,which aggravated the generation of micro-cracks under thermal stress.Higher LED results in higher micro-crack density in the SLM specimen due to higher thermal stress.Mar-M509 specimen fabricated under lower LED exhibits higher tensile strength due to more significant grain refinement.More prominent anisotropy of tensile performance was found in the high LED specimen,which can be attributed to the higher density of micro-cracks and crystallographic texture.Furthermore,the SLM Mar-M509 superalloy exhibits better mechanical properties than the traditional cast technique.In summary,this work can contribute to the development and the future application of SLM-fabricated Co-based superalloy.

Experimental investigation of a Portevin-Le Chatelier band in Ni–Co-based superalloys in relation toγ’precipitates at 500℃

The macroscopically localized deformation behaviors of Ni–Co-based superalloys with differentγ’precipitate content were investigated at 500?C and 1×10-4 s-1 via an in situ method namely,digital image correlation(DIC).The DIC results showed that the serrated flow of the stress–strain curves was accompanied by localized deformation of the specimens.The fracture morphology was characterized mainly by transgranular fracture with numerous dimples in the lowγ’content alloy,and intergranular fracture with large fracture section in the highγ’content alloy.The Portevin–Le Chatelier(PLC)effect occurred in the investigated Ni–Co-based superalloys.Furthermore,the localized deformation of the highγ’content alloy was more severe than that of the lowγ’content alloy,and the band width was slightly larger.Moreover,for the first-time ever,a special propagation feature,namely±60?zigzag bands characterized by head-to-tail connections,was observed in the highγ’content alloy.

Deformation micro-twinning arising at high temperatures in a Ni-Co-based superalloy

Deformation twinning is an important deformation mechanism in nickel-based superalloys. For superalloys, deformation twins are generally observed at low or intermediate temperatures and high strain rates;however, the appearance of microtwins(MTs) at high temperatures has rarely been reported. In this study, transmission electron microscopy(TEM) was used to study MT formation in Ni-Co-based superalloys following compression at 1120 °C/1 s. The deformation behavior was discussed in detail to reveal the mechanism of MT formation. The twinning mechanism at elevated temperatures was theoretically attributed to the low stacking fault energy(SFE) and poor dislocation-driven deformations caused by the high strain rate in specific directions.

Competitive oxidation behavior of Ni-based superalloy GH4738 at extreme temperature

A high thrust-to-weight ratio poses challenges to the high-temperature performance of Ni-based superalloys. The oxidation behavior of GH4738 at extreme temperatures has been investigated by isothermal and non-isothermal experiments. As a result of the competitive diffusion of alloying elements, the oxide scale included an outermost porous oxide layer (OOL), an inner relatively dense oxide layer (IOL), and an internal oxide zone (IOZ), depending on the temperature and time. A high temperature led to the formation of large voids at the IOL/IOZ interface. At 1200℃, the continuity of the Cr-rich oxide layer in the IOL was destroyed, and thus, spallation occurred. Extension of oxidation time contributed to the size of Al-rich oxide particles with the increase in the IOZ. Based on this finding,the oxidation kinetics of GH4738 was discussed, and the corresponding oxidation behavior at 900-1100℃ was predicted.

Recent research progress in the mechanism and suppression of fusion welding-induced liquation cracking of nickel based superalloys

Nickel-based superalloys are extensively used in the crucial hot-section components of industrial gas turbines,aeronautics,and astronautics because of their excellent mechanical properties and corrosion resistance at high temperatures.Fusion welding serves as an effective means for joining and repairing these alloys;however,fusion welding-induced liquation cracking has been a challenging issue.This paper comprehensively reviewed recent liquation cracking,discussing the formation mechanisms,cracking criteria,and remedies.In recent investigations,regulating material composition,changing the preweld heat treatment of the base metal,optimizing the welding process parameters,and applying auxiliary control methods are effective strategies for mitigating cracks.To promote the application of nickel-based superalloys,further research on the combination impact of multiple elements on cracking prevention and specific quantitative criteria for liquation cracking is necessary.

Effect of Ti and Ta content on the oxidation resistance of Co-Ni-based superalloys

Co-Ni-based superalloys are known for their capability to function at elevated temperatures and superior hot corrosion and thermal fatigue resistance.Therefore,these alloys show potential as crucial high-temperature structural materials for aeroengine and gas turbine hot-end components.Our previous work elucidated the influence of Ti and Ta on the high-temperature mechanical properties of alloys.However,the intricate interaction among elements considerably affects the oxidation resistance of alloys.In this paper,Co-35Ni-10Al-2W-5Cr-2Mo-1Nb-xTi-(5−x)Ta alloys(x=1,2,3,4)with varying Ti and Ta contents were designed and compounded,and their oxidation resistance was investigated at the temperature range from 800 to 1000℃.After oxidation at three test conditions,namely,800℃for 200 h,900℃for 200 h,and 1000℃for 50 h,the main structure of the oxide layer of the alloy consisted of spinel,Cr_(2)O_(3),and Al_(2)O_(3)from outside to inside.Oxides consisting of Ta,W,and Mo formed below the Cr_(2)O_(3)layer.The interaction of Ti and Ta imparted the highest oxidation resistance to 3Ti2Ta alloy.Conversely,an excessive amount of Ti or Ta resulted in an adverse effect on the oxidation resistance of the alloys.This study reports the volatilization of W and Mo oxides during the oxidation process of Co-Ni-based cast superalloys with a high Al content for the first time and explains the formation mechanism of holes in the oxide layer.The results provide a basis for gaining insights into the effects of the interaction of alloying elements on the oxidation resistance of the alloys they form.

Microstructure and Wear Resistance of Laser Cladded Co-based Superalloy Coating

Co-based superalloy coating was prepared on the stainless steel surface by laser cladding.The microstructure,phase constitutes and worn surface morphology of the coating were characterized by optical microscope,scanning electron microscope(SEM)with energy dispersive spectrum(EDS)and X-ray diffraction(XRD).The ambient temperature sliding friction and wear property of the coating was also tested.The experiments results showed that:the microstructures of the Co-based superalloy coating are"cellular crystal-coarse dendrite-tiny dendrite"in turn from bottom to surface,which consists ofγ-Co solid solution,Fe2Mo and Co7Mo6.The average micro-hardness of the laser cladding is 632 HV,which is 2 times higher than that of 304 stainless steel matrix.The ambient temperature sliding friction and wear property of the laser cladding is about 1～1.5 times in contrast to that of 304 stainless steel matrix.The better wear resistance of the coating is contributed to solution strengthening of Mo,as well as dispersion strengthening of Fe2Mo and Co7Mo6 hard phases.The failure mechanisms of the coating are pitting fatigue abrasion and grain-abrasion.

A novel high-Cr CoNi-based superalloy with superior high-temperature microstructural stability, oxidation resistance and mechanical properties

A novel multicomponent high-Cr CoNi-based superalloy with superior comprehensive performance was prepared,and the evaluation of its high-temperature microstructural stability,oxidation resistance,and mechanical properties was conducted mainly using its cast polycrystalline alloy.The results disclosed that the morphology of theγ′phase remained stable,and the coarsening rate was slow during the long-term aging at 900–1000℃.The activation energy forγ′precipitate coarsening of alloy 9CoNi-Cr was(402±51)kJ/mol,which is higher compared with those of CMSX-4 and some other Ni-based and Co-based superalloys.Importantly,there was no indica-tion of the formation of topologically close-packed phases during this process.All these factors demonstrated the superior microstructural stability of the alloy.The mass gain of alloy 9CoNi-Cr was 0.6 mg/cm^(2) after oxidation at 1000℃ for 100 h,and the oxidation resistance was comparable to advanced Ni-based superalloys CMSX-4,which can be attributed to the formation of a continuous Al_(2)O_(3) protective layer.Moreover,the compressive yield strength of this cast polycrystalline alloy at high temperatures is clearly higher than that of the conventional Ni-based cast superalloy and the compressive minimum creep rate at 950℃ is comparable to that of the conventional Ni-based cast superalloy,demonstrating the alloy’s good mechanical properties at high temperature.This is partially because high Cr is bene-ficial in improving theγandγ′phase strengths of alloy 9CoNi-Cr.

Cracking on a nickel-based superalloy fabricated by direct energy deposition

Cracks have consistently been a significant challenge limiting the development of additive manufactured nickel-based superalloys.It is essential to investigate the location of cracks and their forming mechanism.This study extensively examines the impact of solidification process,microstructural evolution,and stress concentration on crack initiation during direct energy deposition(DED).The results emphasize that the crack formation is significantly related to large-angle grain boundaries,rapid cooling rates.Cracks caused by large-angle grain boundaries and a fast-cooling rate predominantly appear near the edge of the deposited samples.Liquation cracks are more likely to form near the top of the deposited sample,due to the presence ofγ/γ'eutectics.The secondary dendritic arm and the carbides in the interdendritic regions can obstruct liquid flow during the final stage of solidification,which results in the formation of solidification cracks and voids.This work paves the way to avoid cracks in nickel-based superalloys fabricated by DED,thereby enhancing the performance of superalloys.

A review of linear friction welding of Ni -based superalloys

Ni-based superalloys are one of the most important materials employed in high-temperature applications within the aerospace and nuclear energy industries and in gas turbines due to their excellent corrosion,radiation,fatigue resistance,and high-temperature strength.Linear friction welding(LFW)is a new joining technology with near-net-forming characteristics that can be used for the manu-facture and repair of a wide range of aerospace components.This paper reviews published works on LFW of Ni-based superalloys with the aim of understanding the characteristics of frictional heat generation and extrusion deformation,microstructures,mechanical proper-ties,flash morphology,residual stresses,creep,and fatigue of Ni-based superalloy weldments produced with LFW to enable future optim-um utilization of the LFW process.

MICROSTRUCTURES AND PROPERTIES OF DZ40M Co-BASED SUPERALLOY AFTER LONG-TERM AGEING AT 850℃

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Oxidation behavior of 4774DD1 Ni-based single-crystal superalloy at 980℃ in air

The oxidation behavior of a novel Ni-based single-crystal 4774DD1 superalloy for industrial gas turbine applications was investigated by the isothermal oxidation at 980℃ and discontinuous oxidation weight gain methods.The phase constitution and morphology of surface oxides and the characteristics of the crosssection oxide film were analyzed by XRD,SEM and EDS.Results show that the oxidation kinetics of the 4774DD1 superalloy follows the cubic law,indicating its weak oxidation resistance at this temperature.As the oxidation time increases,the composition of the oxide film evolves as following:One layer consisting of a bottom Al_(2)O_(3)sublayer and an upper(Al_(2)O_(3)+NiO)mixture sublayer after oxidized for 25 h.Then,two layers composed of an outermost small NiO discontinuous grain layer and an internal layer for 75 h.This internal layer is consisted of the bottom Al_(2)O_(3)sublayer,an intermediate narrow CrTaO_(4)sublayer,and an upper(Al_(2)O_(3)+NiO)mixture sublayer.Also two layers comprising an outermost relative continuous NiO layer with large grain size and an internal layer as the oxidation time increases to 125 h.This internal layer is composed of the upper(Al_(2)O_(3)+NiO)mixture sublayer,an intermediate continuous(CrTaO_(4)+NiWO_(4))mixture sublayer,and a bottom Al_(2)O_(3)sublayer.Finally,three layers consisting of an outermost(NiAl2O_(4)+NiCr2O_(4))mixture layer,an intermediate(CrTaO_(4)+NiWO_(4))mixture layer,and a bottom Al_(2)O_(3)layer for 200 h.

Effect of hot isostatic pressure on the microstructure and tensile properties of γ'-strengthened superalloy fabricated through induction-assisted directed energy deposition

The microstructure characteristics and strengthening mechanism of Inconel738LC(IN-738LC) alloy prepared by using induction-assisted directed energy deposition(IDED) were elucidated through the investigation of samples subjected to IDED under 1050℃ preheating with and without hot isostatic pressing(HIP,1190℃,105 MPa,and 3 h).Results show that the as-deposited sample mainly consisted of epitaxial columnar crystals and inhomogeneously distributed γ’ phases in interdendritic and dendritic core regions.After HIP,grain morphology changed negligibly,whereas the size of the γ’ phase became increasingly even.After further heat treatment(HT,1070℃,2 h + 845℃,24 h),the γ’ phase in the as-deposited and HIPed samples presented a bimodal size distribution,whereas that in the as-deposited sample showed a size that remained uneven.The comparison of tensile properties revealed that the tensile strength and uniform elongation of the HIP + HTed sample increased by 5% and 46%,respectively,due to the synergistic deformation of bimodal γ’phases,especially large cubic γ’ phases.Finally,the relationship between phase transformations and plastic deformations in the IDEDed sample was discussed on the basis of generalized stability theory in terms of the trade-off between thermodynamics and kinetics.

Structure characterization of the oxide film on FGH96 superalloy powders with various oxidation degrees

The structure of the oxide film on FGH96 alloy powders significantly influences the mechanical properties of superalloys.In this study,FGH96 alloy powders with various oxygen contents were investigated using high-resolution transmission electron microscopy and atomic probe technology to elucidate the structure evolution of the oxide film.Energy dispersive spectrometer analysis revealed the presence of two distinct components in the oxide film of the alloy powders:amorphous oxide layer covering the γ matrix and amorphous oxide particles above the carbide.The alloying elements within the oxide layer showed a laminated distribution,with Ni,Co,Cr,and Al/Ti,which was attributed to the decreasing oxygen equilibrium pressure as oxygen diffused from the surface into the γ matrix.On the other hand,Ti enrichment was observed in the oxide particles caused by the oxidation and decomposition of the carbide phase.Comparative analysis of the oxide film with oxygen contents of 140,280,and 340 ppm showed similar element distributions,while the thickness of the oxide film varies approximately at 9,14,and 30 nm,respectively.These findings provide valuable insights into the structural analysis of the oxide film on FGH96 alloy powders.

Transient liquid phase bonding of DD5 superalloy using a designed interlayer: microstructure and mechanical properties

Nickel based single crystal superalloy is currently widely used as the material for turbine blades in aerospace engines.However,metallurgical defects during the manufacturing process and damage during harsh environmental service are inevitable challenges for turbine blades.Therefore,bonding techniques play a very important role in the manufacturing and repair of turbine blades.The transient liquid phase(TLP)bonding of DD5 Ni-based single crystal superalloy was performed using the designed H1 interlayer.A new third-generation Ni-based superalloy T1 powder was mixed with H1 powder as another interlayer to improve the mechanical properties of the bonded joints.The res-ults show that,such a designed H1 interlayer is beneficial to the improvement of shear strength of DD5 alloy bonded joints by adjusting the bonding temperature and the prolongation of holding time.The maximum shear strength at room temperature of the joint with H1 interlayer reached 681 MPa when bonded at 1260℃for 3 h.The addition of T1 powder can effectively reduce holding time or relatively lower bond-ing temperature,while maintaining relatively high shear strength.When 1 wt.%T1 powder was mixed into H1 interlayer,the maximum room temperature shear strength of the joint bonded at 1260℃reached 641 MPa,which could be obtained for only 1 h.Considering the bonding temperature and the efficiency,the acceptable process parameter of H1+5 wt.%T1 interlayer was 1240℃/2 h,and the room tem-perature shear strength reached 613 MPa.

PHASE TRANSFORMATION OF Al-Ti COATINGS ON Co-BASE SUPERALLOY DZ40M DURING HIGH TEMPERATURE OXIDATION

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