Microstructual evolution and stability of second generation single crystal nickel-based superalloy DD5

The microstructual evolution and stability of a second generation single crystal (SC) nickel-based superalloy DD5 with minor grain boundary (GB) strengthening elements (C, B and Hf) were studied as a function of as-cast, heat treatment and thermal exposure. The microstructure and composition of the alloy were investigated by optical microscopy, scanning electron microanalysis (SEM), electron probe microanalysis (EPMA), energy dispersive spectrometry (EDS) and extraction analysis. In the as-cast condition,the microstructure observations and composition analysis showed that γ phase was the primary solidification phase and there were three microsegregations in the metal matrix. The morphology of these microsegregations depended on element segregations. After heat treatment, the dendrite cores contained fine and cuboidal-shaped γ′ particles with an average edge length of about 0.5 μm, whileinterdendritic regions contained irregularly-shaped γ′ particles and MC/M23C6 carbides. The mass fraction of γ′ phases was 61.685%.After exposure at 980 °C for 1000 h, no TCP phase was observed in both dendritic and interdendritic regions, indicating a good microstructual stability of the DD5 alloy at 980 °C.

Orientation dependence of transverse tensile properties of nickel-based third generation single crystal superalloy DD9 from 760 to 1100 ℃

At temperatures ranging from 760 to 1100 °C, the tensile properties of a nickel-based third generation single crystal superalloy DD9 with [100],[120] and [110] orientations were studied. The microstructures and fracture surfaces were observed by OM, SEM and TEM. Results show that the tensile strength of [100] specimen is higher than that of [120] and [110] specimens at 760 and 850 °C;while at the temperatures higher than 980 °C, the tensile strength of all specimens has little difference. The fracture mechanisms of [100],[120] and [110] specimens are the same at 760 and 980 °C. At 1100 °C, the fracture surfaces of [100] and [120] specimens are characterized by dimple features;while [110] specimen shows mixed quasi-cleavage and dimple featured fracture surfaces. At 760 °C, obvious superlattice stacking faults (SSFs) are observed only in [100] specimen;while at 1100 °C, the dislocation configurations of all specimens are similar. The difference in the number of potential active slip systems in [100],[120] and [110] specimens during the tensile deformation process is the main reason for the transverse tensile anisotropy.

Microstructure evolution and deformation features of single crystal nickel-based superalloy containing 4.2% Re during creep

By means of microstructure observation and measurement of creep properties,the high temperature creep behaviors of a single crystal nickel-based superalloy containing Re were investigated.Results show that the single crystal nickel-based superalloy containing 4.2% Re possesses a better creep resistance at high temperature.After being crept up to fracture,the various morphologies are displayed in the different areas of the sample,and the γ＇ phase is transformed into the rafted structure along the direction vertical to the applied stress axis in the regions far from the fracture.But the coarsening and twisting extents of the rafted γ＇ phase increase in the regions near the fracture,which is attributed to the occurrence of the larger plastic deformation.In the later stage of creep,the deformation mechanism of the alloy is that the dislocations with [01^-1]and [011] trace features shear into the rafted γ＇ phase.The main/secondary slipping dislocations are alternately activated to twist the rafted γ＇ phase up to the occurrence of creep fracture,which is thought to be the fracture mechanism of the alloy during creep.

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.

TEMPERATURE EFFECT ON LOW-CYCLE FATIGUE BEHAVIOR OF NICKEL-BASED SINGLE CRYSTALLINE SUPERALLOY

The low-cycle fatigue （LCF） behavior of a nickel-based single crystal superalloy with [001] orientation was studied at an intermediate temperature of T0℃ and a higher temperature of To ＋ 250℃ under a constant low strain rate of 10^-3 s^-1 in ambient atmosphere. The superalloy exhibited cyclic tension-compression asymmetry which is dependent on the temperature and applied strain amplitude. Analysis on the fracture surfaces showed that the surface and subsurface casting micropores were the major crack initiation sites. Interior Ta-rich carbides were frequently observed in all specimens. Two distinct types of fracture were suggested by fractogaphy. One type was characterized by Mode-I cracking with a microscopically rough surface at To ＋ 250℃. Whereas the other type at lower temperature T0℃ favored either one or several of the octahedral {111} planes, in contrast to the normal Mode-I growth mode typically observed at low loading frequencies （several Hz）. The failure mechanisms for two cracking modes are shearing of γ＇ precipitates together with the matrix at T0℃ and cracking confined in the matrix and the γ/γ＇interface at To - 250℃.

Creep feed grinding induced gradient microstructures in the superficial layer of turbine blade root of single crystal nickel-based superalloy

The service performance of the turbine blade root of an aero-engine depends on the microstructures in its superficial layer.This work investigated the surface deformation structures of turbine blade root of single crystal nickel-based superalloy produced under different creep feed grinding conditions.Gradient microstructures in the superficial layer were clarified and composed of a severely deformed layer(DFL)with nano-sized grains(48–67 nm)at the topmost surface,a DFL with submicron-sized grains(66–158 nm)and micron-sized laminated structures at the subsurface,and a dislocation accumulated layer extending to the bulk material.The formation of such gradient microstructures was found to be related to the graded variations in the plastic strain and strain rate induced in the creep feed grinding process,which were as high as 6.67 and 8.17×10^(7)s^(−1),respectively.In the current study,the evolution of surface gradient microstructures was essentially a transition process from a coarse single crystal to nano-sized grains and,simultaneously,from one orientation of a single crystal to random orientations of polycrystals,during which the dislocation slips dominated the creep feed grinding induced microstructure deformation of single crystal nickel-based superalloy.

Effects of loading rate and peak load on nanoindentation creep behavior of DD407 Ni-base single crystal superalloy

Nanoindentation experiments were conducted under loading rates of 500–6000μN/s and applied peak loads of 4000-12000μN to measure the creep behavior of DD407 Ni-base single crystal superalloy at room temperature.Experimental results demonstrated that DD407 Ni-base single crystal superalloy had a good creep resistance,but its creep properties were sensitive to the loading rate and peak load.The fitting creep parameters significantly increased with increasing loading rate and peak load based on the Findley’s model,and the corresponding creep mechanism was governed by dislocation based on the calculation of creep stress exponent.During nanoindentation creep tests,it was found that the hardness and reduced modulus decreased with increasing the loading rate and peak load,and through a dimensionless analysis,it was also noted that the effect of the dimensionless loading rate was stronger than that of dimensionless peak load on the creep properties.

High cycle fatigue behavior of the second generation single crystal superalloy DD6

The second generation single crystal superalloy DD6 with 0.10%Hf and 0.34%Hf （in mass fraction） was subjected to high-cycle fatigue （HCF） loading at temperatures of 700 ℃ in ambient atmosphere. SEM was used to determine the initiation site and the failure mechanism. Evolution of the microstructure was investigated by TEM observation. The results show that fatigue limit of DD6 alloy with 0.34%Hf is a little smaller than that of the alloy with 0.10%Hf. The fatigue cracks initiated on the surface or near the surface of the specimens. The crack would propagate along { 111 } octahedral slip planes, rather than perpendicular to the loading axis of specimen. Typical fatigue striation formed in steady propagation of fatigue crack. The fracture mechanisms of the high cycle fatigue of DD6 alloys with 0.10%Hf and 0.34%Hf are quasi-cleavage fracture. Different types of dislocation structures were developed during high cycle fatigue deformation.

Isothermal oxidation behavior of single crystal superalloy DD6

The isothermal oxidation behavior of the second generation single crystal superalloy DD6 was studied at 1050 ℃ and 1100 ℃ in ambient atmosphere.Morphology of oxides was examined by SEM and their composition was analyzed by XRD and EDS.The experimental results show that DD6 alloy obeys subparabolic rate law during oxidation of 100 h at 1050 ℃ and 1100 ℃.The oxide scale exposed at 1050 ℃ is made up of an outer NiO layer with a small amount of Al2O3 and an inner Al2O3 layer.The oxide scale exposed at 1100 ℃ is made up of an outer Al2O3 layer with a small amount of NiO,an intermediate layer,mainly composed of Cr2O3 and TaO2,and an inner Al2O3 layer.The γ＇-free layer was formed under the oxide scale at two temperatures.

Simulation of stray grain formation at the platform during Ni-base single crystal superalloy DD403 casting

The mechanism of stray grain formation at the platform of turbine blade simulator and the effect of withdrawal rate （V） on the stray grain phenomenon have been investigated using a macro-scale ProCAST coupled with a 3D Cel ular Automaton Finite Element （CAFE） model. The results indicate that the stray grains nucleate at the edges of platform at V=150μm·s-1 and 200μm·s-1. Using ProCAST computer simulation software, it was proven that the stray grain formation is signiifcantly dependent on the undercooling and the temperature ifeld distribution in the platform. The macroscopic curvature of the liquidus isotherm becomes markedly concave with an increase in the withdrawal rate. The probability of stray grain formation at the edges of platform can be increased by increasing the withdrawal rate in the range of 70μm·s-1 to 200μm·s-1.

Evolution of interfacial dislocation networks during long term thermal aging in Ni-based single crystal superalloy DD5

Interfacial dislocations found in single crystal superalloys after long term thermal aging have an important effect on mechanical properties. Long term thermal aging tests for DD5 single crystal superalloy were carried out at 1,100 ℃ for 20, 100, 200, 500 and 1000 h, and then cooled by air. The effect of long term thermal aging on the dislocation networks at the γ/γ' interfaces was investigated by FE-SEM. Results showed that during the long term thermal aging at 1,100 ℃, misfit dislocations formed firstly and then reorientation in the(001) interfacial planes occurred. Different types of square or rectangular dislocation network form by dislocation reaction. Square dislocation networks consisting of four groups of dislocations can transform into octagonal dislocation networks, and then form another square dislocation network by dislocation reaction. Rectangular dislocation networks can also transform into hexagonal dislocation networks. The interfacial dislocation networks promote the γ' phase rafting process. The dislocation networks spacings become smaller and smaller, leading to the effective lattice misfit increasing from-0.10% to-0.32%.

A CRYSTALLOGRAPHIC MODEL FOR THE ORIENTATION DEPENDENCE OF LOW CYCLIC FATIGUE PROPERTY OF A NICKEL-BASE SINGLE CRYSTAL SUPERALLOY

Fully reversed low cyclic fatigue (LCF) tests were conducted on [0 0 1], [0 1 2], [(1) over bar 1 2], [0 1 1] and [(1) over bar 1 4] oriented single crystals of nickel-bared superalloy DD3 with different cyclic strain rates at 950 degrees C. The cyclic strain rates were chosen as 1.0 x 10(-2), 1.33 x 10(-3) and 0.33 x 10(-3) s(-1). The octahedral slip systems were confirmed to be activated on all the specimens. The experimental result shows that the fatigue behavior depends an the crystallographic orientation and cyclic strain rate. Except [0 0 1] orientation specimens, it is found from the scanning electron microscopy(SEM) examination that there are typical fatigue striations on the fracture surfaces. These fatigue striations are made up of cracks. The width of the fatigue striations depends on the crystallographic orientation and varies with the total strain range. A simple linear relationship exists between the width and total shear strain range modified by an orientation and strain rate parameter. The nonconformity to the Schmid law of tensile/compressive flaw stress and plastic behavior existed at 95 degrees C, and an orientation and strain rate modified Lall-Chin-Pope ( LCP) model was derived for the nonconformity. The influence of crysrallographic orientation and cyclic strain rate on the LCF behavior can be predicted satisfactorily by the model. In terms of an orientation and strain rate modified total strain range, a model for fatigue life was proposed and used successfully to correlate the fatigue lives studied.

Influence of Co, W and Ti on the Stress-rupture Lives of a Single Crystal Nickel-base Superalloy

The influence of Co, W and Ti on stress-rupture lives of a Ni-Cr-AI-Mo-Ta-Co-W-Ti single crystal nickel-base superalloy has been investigated using a L9 （34） orthogonal array design （OAD） by statistical analysis. At a selected composition range, Ti content was the most important factor to the effect of the stress-rupture lives and then followed by Co content. W content had the minimum effect on stress-rupture lives. The optimal alloy should contain 10 wt pct Co, 8 wt pct W and zero Ti. The optimized alloy also had good microstructural stability during thermal exposure at 870℃ for 500 h.

Research on Interlayer Alloys for Transient Liquid Phase Diffusion Bonding of Single Crystal Nickel Base Superalloy DD6

Transient Liquid Phase Diffusion bonding (TLP bonding) is an effective method to achieve excellent joint of DD6, which is a new generation single crystal superalloy to manufacture aero-engine turbine blades. In this paper, the interlayer alloys for DD6 TLP bonding were designed. The alloy foils with thickness 40 μm ~ 60 μm, width 4 mm were prepared by using a single roller rapid solidification apparatus and the TLP bonding of DD6 was conducted. Then the joint microstructure and alloying elements diffusion behaviors were analyzed. The results indicate that microstructures of interlayer alloys prepared are fine and homogeneous, the melting point range of alloys from 1070°C to 1074°C and their melting temperature interval is merely 20°C, when the chemical composition of alloys are 1.5 ~ 2.0Cr, 3.2 ~ 4.0W, 3.7 ~ 4.5Co, 2.2 ~ 3.0Al, 0.7 ~ 1.0Mo, 3.2B, remain Ni (wt%). When the welding parameters are bonding temperature 1200?C, holding time 8.0 hour and welding pressure 0.3 MPa, the compacted joints obtained and the microstructure of TLP bonding seams were similar to base metal. The bonding joint is composed of weld center zone, isothermal solidification zone and diffusion-affected zone. Within joint, the elements diffusion is sufficient and borides in the diffusion zone are fewer.

NUMERICAL STUDY OF THE NOTCH EFFECT ON THE CREEP BEHAVIOR AND LIFE OF NICKEL-BASE SINGLE CRYSTAL SUPERALLOYS

Numerical calculations of creep damage development and life behavior of circular notched specimens of nickel-base single crystal had been performed. The creep stress distributions depend on the specimen geometry. For a small notch radius, von Mises stress has an especial distribution. The damage distribution is greatly influenced by the notch depth, notch radius as well as notch type. The creep crack initiation place is different for each notched specimen. The characteristics of notch strengthening and notch weakening depend on the notch radius and notch type. For the same notch type, the creep rupture lives decrease with the decreasing of notch radius. A creep life model has been presented for the multiaxial stress states based on the crystallographic slip system theory.

Influence of spiral crystal selector on crystal orientation of single crystal superalloy

To increase efficiency and improve performance, reducing cost and emissions, advanced single crystal Ni-based superalloys are required in aerospace propulsion and power generating gas turbines. With the development of alloy, significant improvements in casting techniques have been achieved by introducing the directionally solidified （DS） casting process followed by single crystal （SX） technique. The deviation of preferred orientation of single crystal superalloys is one of the most important defects in casting. In directional solidification equipment with high temperature gradient, single crystal specimens of DZ417G alloy were prepared successfully by the modified Bridgeman method with spiral grain selector. The orientation was investigated by means of X-ray diffraction （XRD） and electron backscattered diffraction （EBSD）.The results show that the crystal selector with a smaller angle can effectively reduce the deviation of preferred orientation.

High temperature creep-rupture features of nickel-base single crystal superalloy

The creep and rupture behavior of a nickel-base single crystal superalloy with [001] orientation was investigated at temperature of 10001040℃ and stress in the range of 150320MPa. The creep features and microstructure were studied by means of the measurement of creep curves and TEM observation. The results show that all creep curves exhibit a short primary and a dominant accelerated creep stage. From the creep parameters and TEM observations, it is suggested that the primary deformation mechanism has a change from precipitatation shearing by pairs of dislocation in the high applied stress region to dislocations climb around the γ′ particles in the low applied stress region. Furthermore, the detailed failure process and fracture surfaces were analyzed by SEM observation.

Antiphase Boundary Strengthening in a Single Crystal Nickel-base Superalloy

An investigation has been made into strengthening mechanism in a single crystal nickel-base superalloy DD8 by transmission electron microscopy. The results show that the stress rupture strength of the alloy increases with decreasing misfit, and the antiphase boundaries (APBs) formed in the ordered γ' phase, rather than the misfits, play a dominate role in strengthening of the single crystal Ni-base superalloy DD8.There are three kinds of mechanisms for forming the APBs which were observed in the present materials. One is mis-arrangement of the local ordered atoms in the γ' precipitates due to the local strain; the second arises from the 1/2<110> dislocations cutting into the γ', and the third is the formation of the APBs induced by the 1/2<110> matrix dislocation network. The contribution of the antiphase boundary energy to the strength of the alloy can be expressed by:where τ is the resistance to deformation provided by the APB energy; S is the long-range order degree in γ'; Tc is the transition temperature from order to disorder; f is the volume fraction of γ'; rs is the radius of γ'; b is the Burgers vector; a is the lattice constant; G is the shear modulus, and k is the proportional constant.

Review on Additive Manufacturing of Single-Crystal Nickel-based Superalloys

The conventional fabrication process for single-crystal nickel-based superalloy materials is directional solidifica-tion,which is classified as casting.With the rapid development of additive manufacturing(AM)technologies,a novel process for fabricating single-crystal superalloys has become possible.This article reviews recent research on the AM of single-crystal nickel-based superalloys.Laser AM technologies,particularly directed energy deposition,are mainly used to repair single-crystal materials.Electron beam powder bed fusion is an innovative method for the direct fabrication of single-crystal materials.Accordingly,the mechanisms of single-crystal formation during AM are analyzed to elucidate the potential of this process route.Furthermore,this article discusses the challenges faced by AM for single-crystal fabrication,and provides perspectives on the trends of future developments.

Inconsistent creep between dendrite core and interdendritic region under different degrees of elemental inhomogeneity in nickel-based single crystal superalloys

The creep inconsistency between dendrite core and interdendritic region is investigated in a nickel-based single crystal superalloy under 1373 K and 137 MPa.Two specimens with higher and lower degree of elemental inhomogeneity on dendritic structures are compared.For specimen with higher inhomogeneity,stronger segregation of refractory elements reinforces the local strength in dendrite core,but damages the strength in interdendritic region.Creep strain is accumulated faster in interdendritic region giving rise to promoted dislocation shearing inγphase,faster degradation of dislocation networks and facilitated topological inversion of rated structures.Although the segregation of refractory elements produces a high density of topologically close-packed(TCP)phase in dendrite core,faster accumulation of creep strain forms microcracks prior in interdendritic region that gives rise to final rupture of the specimen.In another specimen,increased solid solution time gives rise to overall reduced inhomogeneity.Creep inconsistency is relieved to show more uniform evolution of dislocation substructures and rafting between dendrite core and interdendritic region.The second specimen is ruptured by formation and extension of microcracks along TCP phase although the precipitation of TCP phase is relatively restricted under reduced inhomogeneity.Importantly,the balance of local strength between dendrite core and interdendritic region results in over 40%increase of creep rupture life of the second specimen.