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.

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.

Versatile fluidity test model for cast superalloys and comparison between IN718 and IN939

A spiral fluidity test model of superalloys with 10 mm in height and 3 mm in thickness was designed to evaluate the fluidity of two distinct Ni-based superalloys IN718 and IN939.The factors influencing fluidity are ascertained through comparative analysis utilizing methodologies such as JMat Pro,differential scanning calorimetry and high-temperature confocal laser scanning microscopy.The results show that under identical testing conditions,the fluidity of the IN939 superalloy surpasses that of the IN718 superalloy.When subjected to the same temperature,the melt viscosity and surface tension of IN939 superalloy are considerably reduced relative to those of IN718 superalloy,which is beneficial to improving the melt fluidity.Furthermore,the liquidus temperature and solidification range for the IN939 superalloy are both smaller compared with those of the IN718 superalloy.This condition proves advantageous in delaying dendrite coherency,thereby improving fluidity.

Effect of carbon and boron additions on segregation behavior of directionally solidified nickel-base superalloys with rhenium

The phase transformation temperature, segregation behavior of elements and as-cast microstructure were investigated in experimental nickel-base superalloys with different levels of carbon and boron. The results show that the liquidus temperature decreases gradually but the carbide solvus temperature increases obviously with increasing carbon addition. Minor boron addition to the alloy decreases the liquidus temperature, carbide solvus temperature and solidus temperature slightly. Apart from rhenium, the segregation coefficients of the elements alter insignificantly with the addition of carbon. The segregation behavior of rhenium, tungsten and tantalum become more severe with boron addition. The volume fraction and size of primary carbides increase with increasing carbon addition. The main morphology of the carbides is script-like in the alloys with carbon addition while the carbide sheets tend to be concentrated and coarse in the boron-containing alloys

COMPUTER SIMULATION OF GRAIN BOUNDARY SEGREGATION BEHAVIOR AND MECHANISMS OF STRENGTHENING OF Mg IN Ni-BASED SUPERALLOYS

This paper used EAM and static relaxation method to simulate the grain boundary segregation behavior of Mg in Ni-based superalloys. The results offer a better understanding in the strengthening mechanism of Mg addition in superalloys. The segregation of Mg increases the grain boundary cohesive bond and the vacancy formation energy, and decreases the mobility of grain boundary dislocation. It results in the retardation of creep voids initiation and growth.

Effect of ruthenium on γ' precipitation behavior and evolution in single crystal superalloys

The effect of Ru on γ＇ precipitation behavior and evolution in single crystal superalloys with different Ru contents were investigated by scanning electron microscopy with energy dispersive spectroscopy,3D atomic probing,differential scanning calorimetry.The results show that the solvus of the γ＇ phase decreases gradually with increasing Ru content in the alloys by casting or by the same solution and aging treatments,the alloy with a larger Ru content yields a smaller γ＇ phase.The addition of Ru increases the growth rate and coarsening rate of the γ＇ phase.Ru mainly distributes in the γ phase,which causes more Re and Mo partition into the γ＇ phase,increasing the absolute value of mismatch and the rafting rate of the γ＇ phase.

Solidification characteristics and hot tearing susceptibility of Ni-based superalloys for turbocharger turbine wheel

The solidification characteristics and the hot tearing susceptibility were investigated on two Ni-based superalloys for turbocharger turbine wheel, K418 and K419. The segregation behaviors of the alloying elements and the precipitation phases were also studied. The results show that the solidification behavior of K419 alloy is complicated when compared with K418 due to the interdendritic segregation of many kinds of strong interdendritic partitioning elements in the remaining liquid at the final stage of solidification. The segregation of multiple elements in interdendritic liquid results in an extremely low solidus in K419. A long residual liquid stage is found during the solidification of K419, giving rise to reduced cohesion strength of dendrites and increased sensitivity to hot tearing. A hot tearing susceptibility coefficient（HTS） criterion is proposed based on a hot tearing sensitive model. The HTS value of K419 alloy is larger than that of K418 alloy.

HOT CORROSION BEHAVIOR OF Ni-BASED SUPERALLOYS WITH HIGHER Cr CONTENTS -PART Ⅱ.MECHANISM OF HOT CORROSION BEHAVIOR

Based on the experimental results in the previous paper, the mechanism of the hot corrosion behavior of alloy system Ni-16Cr-gAl-2W- 1Mo-4Co-(0～4)Ti-f(0 ～ 4)Ta-(0～4)Nb (in at%) is investigated. In the Ti and Nb-rich corners, hot corrosion is controlled by the basic fluxing mechanism, and a dense and protective surface scale is formed which results in the better hot corrosion resistance for the alloys in these regions. While in the Ta-rich comer,the basic and acidic mechanisms function alternatively, which results in the catastrophic corrosion by forming the porous and non-protective scale, so the alloys in this region show poor hot corrosion resistance. In addition, the concept of 'effective chromium content' seemed to give a correct prediction of the hot corrosion resistance of such alloy systems.

EFFECT OF P，S AND Si ON THE SOLIDIFICATION，SEGREGATION，MICROSTRUCTURE AND MECHANICAL PROPERTIES IN Fe－Ni BASE SUPERALLOYS

The effects of the trace elements, P, S and Si,on the solidification, segregation,microstructure and mechanical properties of GH761 and In718 alloys were studied.It was found that the segregation of the P,S and Si can be greatly aggravated or relieved by the precipitation taking place during the solidification. In the heat treated state,P enhances the intergranular precipitation in the GH761 alloy.The refinement of P in In718 alloy causes the appearance of a film-like δphase.Si increases the intergranular precipitation of the M_6C and the Laves Phase in the In718 alloy.P, S and Si play diverse roles in the tensile and the stress rupture properties of the GH761 and In718 alloys. The most striking effect is that P significantly prolongs the stress rupture lives of the GH761 and In718 alloys in a wide range of 0.00050.015 wt% .The mechanisms by which P,S and Si influence the superalloys are discussed in the text.

Identification of Iron Oxides Qualitatively/Quantitatively Formed during the High Temperature Oxidation of Superalloys in Air and Steam Environments

Mossbauer spectroscopy has been used to study the morphology of iron oxides formed during the oxidation of superalloys, such as SS-304L （1.4306S）, Incoloy-800H, Incoloy-825, UBHA-25L, Sanicro-28 and Inconel-690, at 1200℃ exposed in air and steam environments for 400 h. The basic aim was to identify and compare the iron oxides qualitatively and quantitatively, formed during the oxidation of these alloys in two environments. The behaviour of alloy UBHA-25L in high temperature oxidation in both environments indicates that it has good oxidation resistance especially in steam, whereas Sanicro-28 has excellent corrosion resistance in steam environment. In air oxidation of Inconel-690 no iron oxide, with established Mossbauer parameters, was detected.

PROPERTIES, WELDABILITY AND APPLICATIONS OF ADVANCED WROUGHT SUPERALLOYS FOR GAS TURBINE ENGINES

Alloy selection and alloy design both require consideration of an array of material attributes, including in-service properties, weldability and fabricability. Critical properties of advanced wrought superalloys for gas turbine applications include high temperature strength, thermal stability, oxidation resistance and fatigue resistance. In this paper, the properties of twelve wrought solid-solution-strengthened and six age-hardenable superalloys are compared. Weldability is an important attribute and can be a major limiting factor in the use of certain alloys. Weldability test methods are discussed and the resistance of alloys to solidification cracking and strain-age cracking is compared. The use of weldability testing in the development of modern wrought su-peralloys is discussed with several examples cited. Finally, alloy selection for gas turbine components is outlined, taking into account both alloy properties and fabricability.

Effects of heat treatment and Re-content on the TCP-phase in two Ni-Mo-Cr-Re superalloys

The volume fraction and morphology of the TCP-phase formed in two kinds of Ni- Mo-Cr-Re superalloys under different heat treatment conditions were investigated in this paper. In Re-5% alloy, with increasing of the heat treatment temperature and prolonging the holding time, the volume fraction of TCP-phase decreased and the TCP-phase size increased. At relatively lower temperature, the TCP-phase prefers to present in the dendrite cores. In Re-10% alloy, the volume fraction and size have the same change tendency as that of in Re-5% alloy, but the morphology will change from needle-like and block-like to sphere when the temperature increases. The TCP-phases formed in these two Ni-Mo-Cr-Re alloys are σ and P phase.

First-principles calculations for the elastic properties of Ni-base model superalloys: Ni/Ni_3Al multilayers

A model system consisting of Ni[001]（100）/Ni3Al[001]（100） multi-layers are studied using the density functional theory in order to explore the elastic properties of single crystal Ni-based superalloys. Simulation results are consistent with the experimental observation that rafted Ni-base superalloys virtually possess a cubic symmetry. The convergence of the elastic properties with respect to the thickness of the multilayers are tested by a series of multilayers from 2γ′＋2γto 10γ′＋10γ atomic layers. The elastic properties are found to vary little with the increase of the multilayer＇s thickness. A Ni/Ni3Al multilayer with 10γ′＋10γ atomic layers （3.54 nm） can be used to simulate the mechanical properties of Ni-base model superalloys. Our calculated elastic constants, bulk modulus, orientation-dependent shear modulus and Young＇s modulus, as well as the Zener anisotropy factor are all compatible with the measured results of Ni-base model superalloys R1 and the advanced commercial superalloys TMS-26, CMSX-4 at a low temperature. The mechanical properties as a function of the γ′ phase volume fraction are calculated by varying the proportion of the γ and γ′ phase in the multilayers. Besides, the mechanical properties of two-phase Ni/Ni3Al multilayer can be well predicted by the Voigt-Reuss-Hill rule of mixtures.

Effect of Ti and Al on microstructure and partitioning behavior of alloying elements in Ni-based powder metallurgy superalloys

The microstructure and partitioning behaviors of alloying elements in the γ and γ′ phases in Ni-based powder metallurgy superalloys with different Ti and Al contents were investigated. The results showed that Ti and Al were mainly enriched in the γ′ phase, partially partitioned in the γ matrix, and slightly distributed in the carbides. Different Ti and Al contents in various alloys influenced the composition and amount of MC carbides but did not influence the MC carbides' morphology. With increasing Ti and Al contents, γ + γ′ fan-type structures formed at the grain boundary, eventually resulting in a coarsened γ′ phase. In addition, the morphology of the secondary γ′ phase transformed from nearly spherical to cuboidal. The saturation degrees of Cr, Co, and Mo in the γ matrix were substantially improved with increasing Ti and Al contents.

HIGH TEMPERATURE CRACK PROPAGATION AND FRACTURE OF SUPERALLOYS

High temperature crack propagation and fracture behavior of disks produced by six superalloys have been studied. Crack propagation rates were determined at 650 creep, fatigue and creep/fatigue interaction conditions. The crack propagation rate is raised with increasing strength of superalloy and is also increased with the dwelling time at maximum stress level of cyclic creep test condition. Crack propagation behavior is closely related to high temperature ductility (such as creep strain and stress rupture elongation). Ductility improvement can increase crack propagation resistance by means of softening heat treatment, controlling grain boundary precipitate and microalloying treatment (such as Mg addition to superalloy). \=

Innovative technologies for powder metallurgy-based disk superalloys: Progress and proposal

Powder metallurgy（PM） superalloys are an important class of high temperature structural materials, key to the rotating components of aero engines. In the purview of the present challenges associated with PM superalloys, two novel approaches namely, powder preparation and the innovative spray-forming technique（for making turbine disk） are proposed and studied.Subsequently, advanced technologies like electrode-induction-melting gas atomization（EIGA）, and spark-plasma discharge spheroidization（SPDS） are introduced, for ceramic-free superalloy powders. Presently, new processing routes are sought after for preparing finer and cleaner raw powders for disk superalloys. The progress of research in spray-formed PM superalloys is first summarized in detail. The spray-formed superalloy disks specifically exhibit excellent mechanical properties. This paper reviews the recent progress in innovative technologies for PM superalloys, with an emphasis on new ideas and approaches, central to the innovation driving techniques like powder processing and spray forming.

Activity coefficients of NiO and CoO in CaO–Al_2O_3–SiO_2 slag and their application to the recycling of Ni–Co–Fe-based end-of-life superalloys via remelting

To design optimal pyrometallurgical processes for nickel and cobalt recycling, and more particularly for the end-of-life process of Ni-Co-Fe-based end-of-life（EoL） superalloys, knowledge of their activity coefficients in slags is essential. In this study, the activity coefficients of NiO and CoO in CaO-Al_2O_3-SiO_2 slag, a candidate slag used for the EoL superalloy remelting process, were measured using gas/slag/metal equilibrium experiments. These activity coefficients were then used to consider the recycling efficiency of nickel and cobalt by remelting EoL superalloys using CaO-Al_2O_3-SiO_2 slag. The activity coefficients of NiO and CoO in CaO-Al_2O_3-SiO_2 slag both show a positive deviation from Raoult＇s law, with values that vary from 1 to 5 depending on the change in basicity. The activity coefficients of NiO and CoO peak in the slag with a composition near B =（%CaO）/（%SiO_2） = 1, where B is the basicity. We observed that controlling the slag composition at approximately B = 1 effectively reduces the cobalt and nickel oxidation losses and promotes the oxidation removal of iron during the remelting process of EoL superalloys.

Hot deformation behavior of FGH96 superalloys

The hot deformation behavior of FGH96 superalloys at 1070-1170℃ and 5×10^-4-2×10^-1 s^-1 were investigated by means of the isothermal compression tests at a Gleeble-1500 thermal mechanical simulator. The results show that dynamic recovery acts as the main softening mechanism below 2×10^-3 s^-1, whereas dynamic recrystallization acts as the main softening mechanism above 2× 10^-3 s^-1 during deformation; the temperature increase caused by the deformation and the corresponding softening stress is negligible; the thermal-mechanical constitutive model to describe the hot deformation behavior is given, and the value of the apparent deformation activation energy （Qdef） is determined to be 354.93 kJ/mol.

An anisotropic micromechanics model for predicting the rafting direction in Ni-based single crystal superalloys

An anisotropic micromechanics model based on the equivalent inclusion method is developed to investigate the rafting direction of Ni-based single crystal superalloys. The micromechanical model considers actual cubic structure and orthogonal anisotropy properties. The von Mises stress, elastic strain energy density, and hydrostatic pressure in dif- ferent inclusions of micromechanical model are calculated when applying a tensile or compressive loading along the [001] direction. The calculated results can successfully pre- dict the rafting direction for alloys exhibiting a positive or a negative mismatch, which are in agreement with pervious experimental and theoretical studies. Moreover, the elastic constant differences and mismatch degree of the matrix and precipitate phases and their influences on the rafting direction are carefully discussed.