Effects of Cr content on microstructure and mechanical properties of single crystal superalloy

Two experimental single crystal superalloys with 2% Cr and 4% Cr (mass fraction) were cast in a directionally solidified furnace, while other alloying element contents were kept unchanged. The effects of Cr content on the microstructure, phase stability, tensile properties at 1100 °C and stress rupture properties at 1070 °C and 160 MPa of the single crystal superalloy were investigated. The results show that the size ofγ′ phase particles become small and uniform, and the cubic shape turns a little regular with the increase of Cr content. Theγ′ directional coarsening and rafting were observed in the 2% Cr and 4% Cr alloys after long term aging (LTA) at 1100 °C. The rafting rate ofγ′ phase increased with increasing Cr content. Needle-shaped topologically close packed (TCP) phases precipitated and grew along fixed direction in both alloys. The precipitating rate and volume fraction of TCP phases significantly increased with the increase of Cr content. The tensile property of the alloy increased and the stress rupture properties of the alloy decreased with the increase of Cr content at high temperature. The increase of Cr content increased the partition ratio of TCP forming elements, Re, W, and Mo, and the saturation degrees of these elements inγ phases increased. Therefore, the high temperature phase stability of the alloy decreased with the increase of Cr content.

Temperature dependence of anisotropic stress-rupture properties of nickel-based single crystal superalloy SRR99

In order to reveal the temperature dependence of anisotropic stress？rupture behavior of SRR99 single crystal superalloys under conditions of temperature ranging from 650 to 1 040 °C and typical stresses,fracture morphologies and microstructure evolution were investigated by SEM and TEM.From the Larson-Miller curves,it is found that single crystal with [001] orientation has the optimum stress rupture property in comparison with [011] and [111] orientations at lower and intermediate temperature.With increasing temperature to 1 040 °C,stress-rupture properties of single crystals with three principal orientations tend to be equivalent.Based on the fracture surface and microstructural observations,superior stress？rupture behavior of single crystal with [001] orientation was rationalized and the effect of misorientation of single crystal on stress rupture property was also discussed.

Effect of carbon on microstructure and mechanical properties of DD99 single crystal superalloy

The effects of carbon on the microstructure and mechanical properties of DD99 single crystal superalloy were investigated. The results show that stress rupture life of DD99 alloy possesses peak value at carbon content of 0.03%(mass fraction). As carbon addition is greater than 0.03%, the stress-rupture life decreases with the increase of carbon content. The tensile strength and yield strength of DD99 alloy reach peak value at 0.08% carbon and 760℃. On the contrary, the tensile strength and yield strength have minimal values at 0.08% carbon and 900℃. The tensile ductility of DD99 alloy basically decreases with the increase of carbon content at 760℃or 900℃. The amount of carbides greatly increases with the addition of carbon content. Dislocation moving is retarded by carbides so that dislocation networks are apt to form, which has an important role on the mechanical properties in DD99 single crystal superalloy.

Influence of Temperature on Stacking Fault Energy and Creep Mechanism of a Single Crystal Nickel-based Superalloy

The influence of temperatures on the stacking fault energies and deformation mechanism of a Re- containing single crystal nickel-based superalloy during creep at elevated temperatures was investigated by means of calculating the stacking fault energy of alloy, measuring creep properties and performing contrast analysis of dislocation configuration. The results show that the alloy at 760 ℃ possesses lower stacking fault energy, and the stacking fault of alloy increases with increasing temperature. The defor- mation mechanism of alloy during creep at 760 ℃ is 7＇ phase sheared by 〈110〉 super-dislocations, which may be decomposed to form the configuration of Shockley partials plus super-lattice intrinsic stacking fault, while the deformation mechanism of alloy during creep at 1070 ℃ is the screw or edge super- dislocations shearing into the rafted 7＇ phase. But during creep at 7（50 and 980 ℃, some super- dislocations shearing into 7＇ phase may cross-slip from the {111} to {100} planes to form the K-W locks with non-plane core structure, which may restrain the dislocations slipping to enhance the creep resis- tance of alloy at high temperature. The interaction between the Re and other elements may decrease the diffusion rate of atoms to improve the microstructure stability, which is thought to be the main reason why the K-W locks are to be kept in the Re-containing superalloy during creep at 980 ℃.

Study on Strength and Life of Anisotropic Single Crystal Blade - Part Ⅱ: Experimental Research

The single crystal blade is one of the key technologies for improving the performance, durability and reliability of aero-engines and ground gas-turbine engines. However, the anisotropic mechanical properties of the single crystal material makes a great deal of difficulties on the development and the application of the single crystal blade, which is a challenge for the engineering application of the single crystal superalloy and the theoretic bases of the application. Some researches on the strength analysis and the life prediction of the anisotropic single crystal blade were carried out by the authors' research team. They are as follows. The crystallographic constitutive models for the plastic and the creep behaviors and the method of the rupture life prediction were established and verified. The tensile or the creep experiments for DD3 single crystal alloy with different orientations under different temperatures and different tensile rates or under different temperatures and different stress levels were carried out. The experimental data and the anisotropic properties at intermediate and high temperatures revealed by the experiments are significant for the application of the single crystal alloy. In addition, the experimental research for a kind of single crystal blade was also made. As the application of the researches the strength analysis and the life prediction were carried out for the single crystal blade of a certain aeroengine. In this part, the experimental research work is describled, and the constitutive models and applications have been described in part I.

Effect of solution cooling rate on the microstructure and creep deformation mechanism of a rhenium-free second-generation single crystal superalloy

Various cooling scenarios(water,oil,air and furnace)were employed to study the impacts of the solution cooling rate(SCR)on the microstructure and creep behavior of a novel single-crystal(SX)superalloy.The results showed that the cubic degree and size of theγphases were inversely proportional to the SCR.The creep life first increased and then dropped dramatically with a reduction in the SCR.The creep life of the sample cooled with air cooling(AC)was the highest,up to 144.90 h at 800℃/750 MPa and160.15 h at 1100℃/137 MPa.During creep at 800℃/750 MPa,the improved creep life of the AC sample was mainly attributed to the fine cubicγphases,which decreased the rate ofγ-phase coarsening and favoured plastic deformation by promoting the active movement of dislocations.The AC helped theγphases become rich in Al,Ti and Ta while depleted in Co and Cr,which enhanced its stacking fault energy,thus promoting the formation of dislocation locks.Meanwhile,the largest negative lattice misfit caused by AC induced denserγ/γinterface dislocation networks at 1100℃/137 MPa,which efficiently reduced the minimum creep rate.The calculated average dislocation spacing results indicated that the smallest density of excess dislocations corresponded to the AC sample,proving its greatest creep resistance.Interestingly,the size of the secondaryγphases first decreased and then increased sharply with decreasing SCR during creep at 1100℃/137 MPa,when fine secondaryγphases had a positive role in the blockage of dislocation movement in the matrix.Eventually,the comprehensive SCR effect was explored to provide more guidance in the design of Re-free SX superalloys.

High Temperature Stress Rupture Anisotropy of a Ni-Based Single Crystal Superalloy

High temperature stress rupture anisotropies of a second generation Ni-base single crystal（SC） superalloy specimens with [001], [011] and [111] orientations under 900 ℃/445 MPa and 1100 ℃/100 MPa have been investigated in the present study, with attentions to the evolution of γ/γ′ microstructure observed by scanning electron microscopy and the dislocation configuration characterized by transmission electron microscopy in each oriented specimen. At 1100 ℃/100 MPa as well as 900 ℃/445 MPa, the single crystal superalloy exhibits obvious stress rupture anisotropic behavior. The [001] oriented specimen has the longest rupture lifetime at 900 ℃/445 MPa, and the [111] oriented sample shows the best rupture strength at 1100 ℃/100 MPa. While the [011] oriented specimen presents the worst rupture lifetime at each testing condition, its stress rupture property at 1100 ℃/100 MPa is clearly improved, compared with900 ℃/445 MPa. The evident stress rupture anisotropy at 900 ℃/445 MPa is mainly attributed to the distinctive movement way of dislocations in each oriented sample. Whereas, at 1100 ℃/100 MPa, together with the individual dislocation configuration, the evolution of γ/γ′ microstructure in each orientation also plays a key role in the apparent stress rupture anisotropy.

An overview of rhenium effect in single-crystal superalloys

Nickel-based single-crystal superalloys are the key materials for the manufacturing and development of advanced aeroengines. Rhenium is a crucial alloying element in the advanced nickel-based single-crystal superalloys for its special strengthening effects. The addition of Re could effectively enhance the creep properties of the single-crystal superalloys; thus, the content of Re is considered as one of the characteristics in different-generation single-crystal superalloys. Owing to the fundamental importance of rhenium to nickel-based single-crystal superalloys, much progress has been made on understanding of the effect of rhenium in the single-crystal superalloys. While the effect of Re doping on the nickelbased superalloys is well documented, the origins of the socalled rhenium effect are still under debate. In this paper,the effect of Re doping on the single-crystal superalloys and progress in understanding the rhenium effect are reviewed. The characteristics of the d-states occupancy in the electronic structure of Re make it the slowest diffusion elements in the single-crystal superalloys, which is undoubtedly responsible for the rhenium effect, while the postulates of Re cluster and the enrichment of Re at the c/c0 interface are still under debate, and the synergistic action of Re with other alloying elements should be further studied.Additionally, the interaction of Re with interfacial dislocations seems to be a promising explanation for the rhenium effect. Finally, the addition of Ru could help suppress topologically close-packed（TCP） phase formation and strengthen the Re doping single-crystal superalloys.Understanding the mechanism of rhenium effect will be beneficial for the effective utilization of Re and the design of low-cost single-crystal superalloys.

基于选区激光熔化镍基单晶高温合金的修复

选区激光熔化技术光斑和热影响区小,成形精度高,可对镍基单晶高温合金叶片进行有效的修复以延长使用寿命。本工作选用了一种具有中等体积分数γ′相的合金粉末,研究了在单晶CM247LC基板上进行外延生长过程中该合金粉末的显微组织演变规律以及力学性能。结果表明:修复界面的熔池宽深比大于4时,沉积区与基体能形成良好的结合界面以及较小的晶粒取向差。通过增大扫描速率和降低激光功率可以有效减小沉积区裂纹密度,沉积组织以沿沉积方向生长的柱状枝晶为主,沉积层越高,冷却速率越小,枝晶间距和晶粒取向差越大。通过打印参数优化,最终得到了裂纹密度低、晶粒取向单一、且与单晶基板结合优异的镍基单晶高温合金沉积层,其抗拉强度为1094 MPa,伸长率为21%。

激光冲击强化对镍基单晶高温合金SRR99组织及性能的影响

目的解决镍基单晶高温合金航空发动机涡轮叶片在服役时发生表面损伤的问题,探究激光冲击强化对镍基单晶高温合金SRR99的强化变形机制。方法采用高功率(8J)短脉冲激光分别对试样进行1、2、3次表面强化,使用白光干涉仪、显微硬度仪、X射线分析仪对强化前后的镍基单晶高温合金试样表面形貌、粗糙度、显微硬度、残余应力进行测试,通过扫描电子显微镜、透射电子显微镜和X射线衍射仪分析激光冲击强化对镍基单晶高温合金微观组织和物相组成的影响。结果经过1、2、3次激光冲击后,单晶高温合金试样表面发生了塑性变形,表面凹坑随着冲击次数的增加逐渐加深,表面粗糙度分别为1.566、1.868、2.265μm,显微硬度分别增加了15.3%、25.8%、32.1%,表面残余压应力分别提高为–790、–870、–917MPa。经强化后,试样表层形成了畸变层,γ′相的面积和体积分数均增大,合金未发生相变,但两相发生了严重的晶格畸变,晶格常数和晶面间距的变化导致两相晶格发生失配,经强化后在试样表层γ′强化相、γ通道、γ/γ′界面观察到大量位错结构,此外还观察到贯穿γ′相、γ相的位错滑移带和致密的位错网络。结论激光冲击强化技术可使镍基单晶高温合金SRR99发生塑性变形,在其表层内部形成高密度位错网络结构,加工硬化效果显著,提高了基体表面的显微硬度和残余应力。

无保护层纳秒脉冲激光强化对DD5单晶合金耐磨性能的影响

目的提高发动机涡轮叶片榫头材料DD5单晶高温合金的高温耐磨性能。方法采用不同能量的无保护层纳秒脉冲激光对DD5单晶合金试样表面进行处理,利用摩擦磨损试验机获得DD5单晶合金在650℃下的摩擦磨损性能参数,并通过显微硬度计、扫描电子显微镜、能谱仪、共聚焦三维表面轮廓仪对磨损前后的DD5单晶试件进行表征分析,揭示纳秒脉冲激光强化技术提高单晶高温合金耐磨性能的机理。结果采用纳秒脉冲激光处理DD5单晶高温合金后,材料表层发生了重熔现象,并在重熔层中生成了弥散分布的铝的氧化物颗粒,其粒径为5~50nm;纳秒脉冲激光处理后产生的弥散分布的氧化铝颗粒为硬质相,它提升了单晶表面的显微硬度;经纳秒脉冲激光处理后,试样的磨损率降低了19.7%~37.6%,单晶合金的磨损机制以磨粒磨损为主。结论经纳秒脉冲激光处理后,单晶表面生成了含有弥散分布的纳米氧化铝颗粒的重熔层,在它与激光诱导的等离子体冲击波产生的硬化层的共同作用下,提升了镍基单晶高温合金在高温下的耐磨性能。

不同取向镍基单晶高温合金650℃原位拉伸

镍基单晶高温合金作为飞机涡轮发动机叶片的主要使用材料,其在服役过程中受到各向应力作用产生变形导致材料失效,因此本文基于课题组自主研发的原位拉伸设备对[140]取向、[340]取向、[122]取向的镍基单晶高温样品进行了650℃原位拉伸。其中[140]取向样品在屈服阶段后样品硬化到塑性变形后期出现了幅度较小的应力下降,最后样品在应力作用下滑移迹线所在的基体发生开裂,裂纹沿着滑移迹线所在方向扩展至样品断裂。[340]取向样品在整个塑性变形阶段,样品的应力持续下降,孔洞缺陷处形成缺陷导致材料失效。[122]取向样品一直处于硬化阶段,到塑性变形后期样品出现了应力的下降,跟[340]取向样品失效方式相同,孔洞开裂形成裂纹源导致材料失效。本文针对三种取向样品的力学性能,塑性变形过程中的滑移情况以及对应的施密特因子变化、样品失效的方式进行了分析,对合金在真实服役过程中提高其服役寿命具有重要意义。

单晶合金激光增材修复接头组织和性能研究

采用激光熔化沉积技术对DD6单晶高温合金进行修复,利用光学显微镜、扫描电镜和显微硬度仪对单晶母材和增材修复接头的组织特征和力学性能进行对比研究。结果表明:激光熔化沉积修复组织为外延生长的定向凝固柱状晶组织,由γ相基体和少量晶间MC型碳化物组成;DD6单晶合金基体热影响区微观形貌和物相组成与母材相似,但其γ′相的尺寸(≤0.2μm)更小,且γ′/γ的比例明显降低。经激光熔化沉积修复后,增材修复区的显微硬度可达450~470 HV,显著高于DD6单晶基体,具有更优异的耐磨损性能。

DD26单晶高温合金钎焊接头微观组织与力学性能研究

采用NiNbCoWCrAlSiMo钎料,在1225℃/30 min钎焊条件下开展了DD26单晶高温合金的钎焊试验,分析了0.05 mm、0.20 mm两种钎焊间隙对应接头的微观组织和性能。研究发现,接头组织主要由颗粒状的γ+γ′双相组织,以及分布在颗粒相之间的富W相和Ni–Nb(Si)相构成。当钎焊间隙为0.05 mm时,接头室温抗拉强度为614 MPa,达到DD26单晶合金的75.9%;1000℃抗拉强度为466 MPa,达到DD26单晶合金的78.8%;1000℃/75MPa条件下的持久寿命最高可达44.6 h。当钎焊间隙为0.20 mm时,接头室温抗拉强度为686 MPa,达到DD26单晶合金的84.8%;1000℃抗拉强度为479 MPa,达到DD26单晶合金的81.0%;1000℃/75 MPa条件下的持久寿命最高可达17.5 h。焊后热处理对间隙0.05 mm的接头持久性能影响不明显,间隙0.20 mm的接头持久性能在热处理后有所提升。断口分析发现,接头断裂表现出裂纹沿颗粒状的γ+γ'双相组织边缘扩展的特征。

镍基单晶高温合金车削力及刀具磨损研究

镍基单晶高温合金性能优越是航空发动机热端部件如涡轮盘的理想材料,然而镍基单晶高温合金车削加工存在切削力大和刀具磨损严重等问题,限制了零件的加工质量和效率。通过镍基单晶高温合金单因素车削试验,分析了不同车削工艺参数对车削力F_(∑)的影响规律,探究了镍基单晶高温合金刀具磨损机理,提出了防止切削力过大和减缓刀具磨损的措施。试验结果表明车削镍基单晶高温合金车削力F_(∑)随着切削速度vs的增大而减小,而随着进给速度v_(w)和切削深度a_(p)的增大而变大;刀具主要出现磨粒磨损、粘结磨损和涂层剥落3种损伤形式。

DD419镍基单晶高温合金980℃下低周疲劳行为研究

对DD419镍基单晶高温合金在980℃下的低周疲劳行为进行试验研究,并对疲劳数据进行分析,获得该温度下合金疲劳参数。结果表明:该合金低周疲劳变形过程中,弹性变形起主要作用,塑性变形较低;循环应力响应行为以先循环软化、再趋于稳定为主要方式,并且随着应力幅的增加,循环寿命不断降低。低应变幅下,合金的疲劳断裂表现为脆性断裂的特征,并呈现出明显的多源疲劳特征,微观断口形貌的主要特征是出现准解理台阶,可判断准解理断裂是主要的断裂机制。

含空洞镍基单晶高温合金力学性能的分子动力学研究

镍基单晶高温合金因其优异的性能在航空航天方面应用广泛,但是在制造过程中,不可避免有空洞缺陷的产生,从而影响合金力学性能。通过分子动力学模拟研究温度、应变速率和空洞形状对镍基单晶高温合金拉伸力学性能和位错演化的影响。结果表明:温度和应变速率影响材料力学性能,温度增加,杨氏模量减小,屈服强度减小,材料强度降低;应变速率增加,材料的杨氏模量不变,屈服强度增大。此外,空洞的存在降低了材料的强度和杨氏模量。不同形状空洞对杨氏模量影响相同,对材料强度的影响不同。菱形空洞模型由于存在锐角,位错更容易聚集,屈服强度更小,在拉伸过程中更容易断裂变形。

DD5与GH3039高温合金钎焊接头的微观组织与力学性能研究

采用Co50NiCrWB钎料在1160℃/15 min条件下进行了熔化润湿试验,并钎焊得到DD5与GH3039异质高温合金接头,分析了接头的显微组织和力学性能。试验结果表明,Co50NiCrWB钎料在DD5和GH3039高温合金表面的润湿性能良好,接头包括钎料反应区与扩散影响区,反应区主要物相为溶有Cr的Ni–Co基固溶体、富Cr硼化物相和富Co、Cr、W、Re的硼化物相。钎焊接头在900℃的拉伸性能平均值达到193 MPa,900℃/40 MPa下的接头持久寿命最高达到221 h。拉伸试样断口观察表明断裂发生在钎料反应区,呈脆性断裂特征。

镍基单晶高温合金研究进展

单晶高温合金因具有较高的高温强度、优异的蠕变与疲劳抗力以及良好的抗氧化性、抗热腐蚀性、组织稳定性和使用可靠性,广泛应用于涡轮发动机等先进动力推进系统涡轮叶片等部件。由于采用定向凝固工艺消除了晶界,单晶高温合金明显减少了降低熔点的晶界强化元素,提高了合金的初熔温度,能够在较高温度范围进行固溶和时效处理,其高温强度比等轴晶和定向柱晶高温合金也大幅度提高。经过几十年的发展,单晶高温合金已经在合金设计方法、组织结构与力学性能关系、纯净化冶炼工艺和定向凝固工艺等方面取得了重要进展。从单晶高温合金成分特点、合金元素作用、强化机理、力学性能各向异性、凝固过程及缺陷控制、单晶制备工艺等方面,简要介绍了单晶高温合金的主要研究进展。

Ni基高温单晶合金结构强度与寿命研究方法分析

Ｎｉ基单晶制叶片已在国外一些高性能飞机发动机上得到了实际应用，文中对该材料的一些高温力学性能做了归纳，对迄今单晶结构变形、强度与寿命处理方法及其局限性作了评述，进而对该领域的发展方向进行了初步探讨。