New approach for assessing the weldability of precipitation-strengthened nickel-base superalloys

A new procedure was proposed for evaluating the weldability of nickel-base superalloys. The theory is on the basis of two microstructural patterns. In pattern I, the weld microstructure exhibits severe alloying segregation, many low-melting eutectic structures, and low weldability. The weld requires a weaker etchant and a shorter time for etching. In pattern Ⅱ, the weld microstructure displays less alloying segregation, low quantity of eutectic structures, and high weldability. The weld needs a stronger etchant and a longer time for etching. Five superalloys containing different amounts of Nb and Ti were designed to verify the patterns. After welding operations, the welds were etched by four etchants with different corrosivities. The weldability was determined by TG-DSC measurements. The metallography and weldability results confirmed the theoretic patterns. Finally, the etchant corrosivity and etching time were proposed as new criteria to evaluate the weldability of nickel-base superalloys.

Hot Cracking Susceptibility of 800H and 825 Nickel-Base Superalloys during Welding via Spot Varestraint Test

Hot cracking susceptibility of fillers 52 and 82 in 800H and 825 nickel-base superalloys was discussed using the Spot Varestraint test.The fillers of 52 and 82 were added into nickel-base superalloys via a gas tungsten arc welding(GTAW).Experimental results showed that the hot cracking sensitivity of the nickel-base superalloys with filler at high temperature was lower than that without filler.The hot cracking sensitivity had a slight effect when the filler 82 was added.The total length of crack was increased,the liquid-solid(L-S)two-phase range is higher so that the hot cracking susceptibility will be raised.The morphologies of cracks included the intergranular crack in the molten pool,molten pool of solidification cracking,heat-affected zone of intergranular cracks,and transgranular crack in the heat-affected zone.

Nickel-base superalloys for USC power plants

The advanced ultra-supercritical power plants of the future will utilize steam pressures and temperatures that are too high for traditional ferritic steels,thus requiring austenitic materials.Older nickel-base superalloys such as 263 and 617 were initially evaluated under the European THERMIE project beginning in the 1990s.An entirely new age-hardened alloy 740 which possesses exceptional fireside corrosion resistance and creep strength was also developed for boiler tubing capable of serving at 700C.Subsequently,interest in the USA considered other product forms such as steam header piping and steam turbine forgings for service as high as 760C.A more stable and weldable alloy version now called 740H was developed to meet these more demanding conditions.This paper summarizes the current status of work on alloys 740 and 740H.

SPRAY FORMED NICKEL-BASE SUPERALLOYS

In this paper,part of the research and development work in the field of spray formed superalloys at BIAM of China is briefly summarized. With an experimental spray forming facility,whose melting capacity is suitable for making disk and columnar shaped integral-dense and clean Ni-base superalloy preforms with low oxygen content,fine grain, uniform chemistry and improved forgeability, a series of Ni-base superalloys have been spray atomized and deposited, among which three alloys have been chosen for microstructural and mechanical properties evaluation.

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.

Recent advances in nickel-based catalysts in eCO_(2)RR for carbon neutrality

The excessive use of nonrenewable energy has brought about serious greenhouse effect.Converting CO_(2) into high-value-added chemicals is undoubtedly the best choice to solve energy problems.Due to the excellent cost-effectiveness and dramatic catalytic performance,nickel-based catalysts have been considered as the most promising candidates for the electrocatalytic CO_(2) reduction reaction(eCO_(2)RR).In this work,the electrocatalytic reduction mechanism of CO_(2) over Ni-based materials is reviewed.The strategies to improve the eCO_(2)RR performance are emphasized.Moreover,the research on Ni-based materials for syngas generation is briefly summarized.Finally,the prospects of nickel-based materials in the eCO_(2)RR are provided with the hope of improving transition-metal-based electrocatalysts for eCO_(2)RR in the future.

Effect of Interface Form on Creep Failure and Life of Dissimilar Metal Welds Involving Nickel-Based Weld Metal and Ferritic Base Metal

For dissimilar metal welds(DMWs)involving nickel-based weld metal(WM)and ferritic heat resistant steel base metal(BM)in power plants,there must be an interface between WM and BM,and this interface suffers mechanical and microstructure mismatches and is often the rupture location of premature failure.In this study,a new form of WM/BM interface form,namely double Y-type interface was designed for the DMWs.Creep behaviors and life of DMWs containing double Y-type interface and conventional I-type interface were compared by finite element analysis and creep tests,and creep failure mechanisms were investigated by stress-strain analysis and microstructure characterization.By applying double Y-type interface instead of conventional I-type interface,failure location of DMW could be shifted from the WM/ferritic heat-affected zone(HAZ)interface into the ferritic HAZ or even the ferritic BM,and the failure mode change improved the creep life of DMW.The interface premature failure of I-type interface DMW was related to the coupling effect of microstructure degradation,stress and strain concentrations,and oxide notch on the WM/HAZ interface.The creep failure of double Y-type interface DMW was the result of Type IV fracture due to the creep voids and micro-cracks on fine-grain boundaries in HAZ,which was a result of the matrix softening of HAZ and lack of precipitate pinning at fine-grain boundaries.The double Y-type interface form separated the stress and strain concentrations in DMW from the WM/HAZ interface,preventing the trigger effect of oxide notch on interface failure and inhibiting the interfacial microstructure cracking.It is a novel scheme to prolong creep life and enhance reliability of DMW,by means of optimizing the interface form,decoupling the damage factors from WM/HAZ interface,and then changing the failure mechanism and shifting the failure location.

On establishment of novel constitutive model for directionally solidified nickel-based superalloys utilizing machine learning methods

To enhance the accuracy of mechanical simulation in the directional solidification process of turbine blades for heavy-duty gas turbines,a new constitutive model that employs machine learning methods was developed.This model incorporates incremental learning and transfer learning,thus improves the predictive accuracy and generalization performance.To account for the anisotropy of the directionally solidified alloy,a deformation direction parameter is added to the model,enabling prediction of the stress-strain relationship of the alloy under different deformation directions.The predictive capabilities of both models are evaluated using correlation coefficient(R),average relative error(δ),and value of relative error(RE).Compared to the traditional model,the machine learning constitutive model achieves higher prediction accuracy and better generalization performance.This offers a new approach for the establishment of flow constitutive models for other directionally solidified and single-crystal superalloys.

Effect of Solidification Condition and Carbon Content on the Morphology of MC Carbide in Directionally Solidified Nickel-base Superalloys

Evolution of the morphology of MC carbides with the change of cooling rate and carbon content in two kinds of nickel-base superalloys, K417 G and DD33, has been investigated. The morphology of MC carbides evolves from faceted to script-like with increasing cooling rate. Varying the carbon content from 40X10-6 to 320X10-6, the morphology of carbides changes from blocky, rod-like into script-like. Scanning electron microscopy observation of deep-etched samples indicates that these carbides evolve from octahedral to dendritic and then into welldeveloped dendrites accordingly in a three-dimensional manner. The morphology evolution is discussed from the viewpoint of the preferential growth orientation of fcc crystals and the carbide growth rate during directional solidification.

Effect of the capsule on deformation and densification behavior of nickel-based superalloy compact during hot isostatic pressing

The Shima yield criterion used in finite element analysis for nickel-based superalloy powder compact during hot isostatic pressing(HIP) was modified through uniaxial compression experiments. The influence of cylindrical capsule characteristics on FGH4096M superalloy powder compact deformation and densification behavior during HIP was investigated through simulations and experiments. Results revealed the simulation shrinkage prediction fitted well with the experimental shrinkage including a maximum shrinkage error of 1.5%. It was shown that the axial shrinkage was 1.7% higher than radial shrinkage for a cylindrical capsule with the size of ∮50 mm × 100 mm due to the force arm difference along the axial and radial direction of the capsule. The stress deviated from the isostatic state in the capsule led to the uneven shrinkage and non-uniform densification of the powder compact. The ratio of the maximum radial displacement to axial displacement increased from0.47 to 0.75 with the capsule thickness increasing from 2 to 4 mm. The pressure transmission is related to the capsule thickness, the capsule material performance, and physical parameters in the HIP 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.

Microstructural evolution and castability prediction in newly designed modern third-generation nickel-based superalloys

The present research aims to establish a quantitative relation between microstructure and chemical composition （i.e., Ti, Al, and Nb） of newly designed nickel-based superalloys. This research attempts to identify an optimum microstructure at which the minimum quanti- fies of γ/γ＇ and γ/γ＂ compounds are achieved and the best castability is predicted. The results demonstrate that the highest quantity of inter- metallic eutectics （i.e., 41.5wt%） is formed at 9.8wt% （Ti ＋ A1）. A significant quantity of intermetallics formed in superalloy 1 （with a com- position of7 - 9.8wt% （Ti ＋ A1））, which can deteriorate its castability. The type and morphology of the eutectics changed and the amount considerably decreased with decreasing Ti ＋ A1 content in superalloy 2 （with a composition ofy - 7.6wt% （Ti ＋ A1）, 1.Swt% Nb）. Thus, it is predicted that the castability would improve for superalloy 2. The same trend was observed for superalloy 4 （with a composition of 7 - 3.7wt% （Ti ＋ A1）, 4.4wt% Nb）. This means that the amount of Laves increases with increasing Nb （to 4.4wt%） and decreasing Ti ＋ A1 （to 3.7wt%） in su- peralloy 4. The best castability was predicted for superalloy 3 （with a composition ofy - 5.7wt% （Ti ＋ A1）, 2.8wt% Nb）.

Evolution of Grain Selection in Spiral Selector during Directional Solidification of Nickel-base Superalloys

The process of grain selection in the spiral selector was investigated by both a ProCAST simulation based on a cellular automaton finite element（CAFE） model and experimental confirmation.The results show that the height of starter block,the spiral diameter and initial angle play an important role in grain selection.The dimension of selector should be maintained in a stable range to optimize the grain orientation and select a single crystal efficiently.A selector which can efficiently select a single crystal had been successfully designed.Grain orientation fluctuation in the spiral part was also studied by means of the variation of thermal condition.

Determination of Aluminum in Nickel-Based Superalloys by Using Laser-Induced Breakdown Spectroscopy

Laser-induced breakdown spectroscopy （LIBS） was developed to detect aluminum in nickel-based superalloys （K417, GH4033, DZ125L, З ∏742y） using a non-intensified, non-gated, low-cost detection system. The precision of LIBS depends strongly on the experimental conditions. The calibration curves of Al（I）394.4 nm and Al（I）396.2 nm under the optimum experimental parameters are presented. Finally the limit of detection （LOD） for aluminum is calculated from the experimental data, which is in the range of 0.09% to 0.1% by weight.

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.

Influence of heat treatments on incipient melting structures of DD5 nickel-based single crystal superalloy

The evolution of microstructure and formation mechanism of incipient melting microstructure of DD5 single crystal superalloy during solution heat treatment were studied by scanning electron microscopy(SEM),electron probe microanalysis(EPMA),and energy dispersive spectroscopy(EDS).The solidus and liquidus of single crystal alloy were obtained by differential scanning calorimetry(DSC).Results show that the mosaic-like eutectic and fan-like eutectic are dissolved at first,and the coarseγ'phase is dissolved later during the solution heat treatment of 1,390°C/2 h+1,310°C/4 h+1,320°C/10 h+air cooling(AC).The composition segregations of Al,Ta,W and Re are 0.99,0.96,1.04 and 1.16,respectively,which close to 1.The incipient melting is caused by the low local temperature of the alloy,and the micropore region with a lower melting point is the preferred position for incipient melting.

THE ROLE OF NIOBIUM IN NICKEL-BASED SUPERALLOYS AND CHARACTERIZATION OF PM ALLOY EP741NP

The role of niobium in nickel-based superalloys is reviewed. The importance of niobium as a strengthener is discussed. New developments in nickel-based superalloys are also briefly mentioned, including some results that show improved resistance to sulfidation by niobium. Research results from a current program on the role of niobium in the Russian powder metallurgy alloy EP741NP are presented. Future research plans on the role of niobium in superalloys are also discussed.

Spin and spin-orbit coupling effects in nickel-based superalloys:A first-principles study on Ni_(3)Al doped with Ta/W/Re

Heavy elements(X=Ta/W/Re)play an important role in the performance of superalloys,which enhance the strength,anti-oxidation,creep resistance,and anti-corrosiveness of alloy materials in a high-temperature environment.In the present research,the heavy element doping effects in FCC-Ni(γ)and Ni_(3)Al(γ')systems are investigated in terms of their thermodynamic and mechanical properties,as well as electronic structures.The lattice constant,bulk modulus,elastic constant,and dopant formation energy in non-spin,spin polarized,and spin-orbit coupling(SOC)calculations are compared.The results show that the SOC effects are important in accurate electronic structure calculations for alloys with heavy elements.We find that including spin for bothγandγ'phases is necessary and sufficient for most cases,but the dopant formation energy is sensitive to different spin effects,for instance,in the absence of SOC,even spin-polarized calculations give 1%to 9%variance in the dopant formation energy in our model.Electronic structures calculations indicate that spin polarization causes a split in the metal d states,and SOC introduces a variance in the spin-up and spin-down states of the d states of heavy metals and reduces the magnetic moment of the system.

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.