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℃.

DENDRITE REFINING AND EUTECTIC TRANSFORMATION BEHAVIOR OF NICKEL-BASE SINGLE CRYSTAL (NBSC) SUPERALLOY

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Influence of Pre-Compressive Creep on Internal Friction Stress and Creep Parameters of Nickel-Base Single Crystal Superalloys

By means of pre-compressive creep treatment, the cubic γ′ phase in a nickel base single crystal superalloy is transformed into the P-type rafted structure. And the influence of the pre-compressive creep on the internal friction stress and creep lifetimes of the superalloy are investigated by means of the measurement of the creep curves and microstructure observation. Results show that, compared to the P-type structure alloy, the full heat treated state alloy displays a bigger internal friction stress value of dislocation motion during steady state creep and a longer creep lifetimes. The creep activation energies of the full heat treated and P-type structures alloys are measured to be 462 kJ/mol and 412 kJ/mol, respectively. Thereinto, the P-type rafted γ′ phase in the alloy is transformed into the N-type structure during tensile creep. And the N-type γ′ phase transformed from the P-type structure displays a shorter size in length, this is a main reason of the P-type structure alloy possessing a shorter creep lifetimes due to creep dislocation moving easily over the rafted γ′ phase.

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.

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.

Life Prediction Model for a Nickel-base Single Crystal Superalloy DD3

The possibility of a life prediction model for nickel base single crystal blades has been studied. The fatigue creep (FC) and thermal fatigue creep(TMFC) as well as creep experiments have been carried out with different hold time of DD3. The hold time and the frequency as well as the temperature range are the main factors influencing the life. An emphasis has been put on the micro mechanism of the rupture of creep, FC and TMFC. Two main factors are the voiding and degeneration of the material for the cre...

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.

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.

Microstructure Evolution of a Single Crystal Nickel-Base Superalloy During Heat Treatment and Creep

Microstructure evolution of a single crystal nickel-base superalloy during heat treatment and tensile creep at 1010°C and 248 MPa for 30h was observed and analyzed. Internal stresses because of lattice mismatch between and / phase provided the driving force for / shape evolution during heat treatment. More than 65 vol. % distorted cubic phase keeping coherency with the y matrix precipitated after solution at 1295°C for 32h. The shape of phase was perfectly cubic with increasing precipitate size during the two-step aging treatment. Due to the applied stress and internal stress field the continuous y1/ lamellar structure perpendicular to the applied stress was formed after 30h tensile creep.

Influence of microstructure stability on creep properties of single crystal nickel base superalloys

The influence of microstructure stability on the creep properties of single crystal nickel-based superalloys was investigated by means of the measurement of the creep curves and microstructure observation. Results show that the superalloy with 4%(mass fraction)W in Ni-Al-Cr-Ta-Co-5.5%Mo-x%W systems displays a better microstructure stability, but theμphase is precipitated in the superalloy with 6% W during aging. The strip-likeμphase is precipitated to be parallel or perpendicular to each other along the <110> orientation, and grown into the slice-like morphology along the {111} planes. The superalloy with 4%W displays a better creep rupture lifetime under the applied stress of 200 MPa at 982℃, but the creep lifetime of alloy is obviously decreased with the increase of the element W content up to 6%. The fact that theμphase is precipitated in the superalloy with 6% W during applied stress and unstress aging results in the appearance of the poor regions for the refractory elements. This is one of the main reasons for reducing the creep rupture lifetime of the superalloy.

Effects of Ru on the microstructure and phase stability of a single crystal superalloy

Two experimental single crystal superalloys, the Ru-free alloy and the Ru-containing alloy with [001 ] orientation, were cast in a directionally solidified furnace, while other alloying element contents were kept unchanged. The effects of Ru on the microstructure and phase stability of the single crystal superalloy were investigated, y＇ directional coarsening and rafting were observed in the Ru-free alloy and Ru-containing alloy after long-term aging at 1070~C for 800 h. Needle-shaped o topologically close packed （TCP） phases precipitated and grew along the fixed direction in both the alloys. The precipitating rate and volume fraction of TCP phases decreased significantly by adding Ru. The compositions ofy and y＇ phases measured using an energy-dispersive X-ray spectroscope （EDS） in transmission electron microscopy （TEM） analysis showed that the addition of Ru lessened the partition ratio of TCP forming elements, Re, W and Mo, and decreased the satu- ration degrees of these elements in y phase, which can enable the Ru-containing alloy to be more resistant to the formation of TCP phases. It is indicated that the addition of Ru to the Ni-based single crystal superalloy with high content of the refractory alloying element can enhance phase stability.

Isothermal oxidation behavior of a new Re-free nickel-based single-crystal superalloy at 950℃

The isothermal oxidation behavior of a new Refree nickel-based single-crystal superalloy in air at 950 ℃ for 200 h was studied by scanning electron microscopy（SEM）with energy-dispersive spectroscopy（EDS）and X-ray diffraction（XRD）.The results indicate that oxidation kinetics obeys parabolic law approximately,and the mass gain increases rapidly during initial oxidation stage and then gradually slows down.The oxidation scales are composed of three layers：the outer layer mainly consists of NiO with a small amount of CoO;the intermediate layer is mainly composed of Cr_2O_3 with a small amount of spinel compounds such as CrTaO_4,NiCr_2O_4,CoCrAl_2O_4,CoAl_2O_4,and NiAl_2O_4;and the inner layer is composed of Al_2O_3.Inner Al_2O_3 layer suppresses the diffusion of elements between oxygen and alloy elements,slows down the alloy oxidation speed,and also suppresses the growth of the oxide scale and reduces the oxidation rate,which is agreeable with the oxidation kinetics.

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 ℃.

Anisotropic Creep Rupture Properties of a Nickel-base Single Crystal Superalloy at High Temperature

The creep rupture properties of a single crystal superalloy were tested at 975℃/255 MPa as a function of the deviation degrees from [001].The misorientation of the specimens away from [001] distributed approximately along a line between [001]-[011] and [001]-[111] boundaries in the triangle of the stereographic projection.Creep rupture lifetimes of the specimens were not sensitive to the misorientation until the deviation degree exceeded ～30 deg.Two steps of lattice rotation were found in all specimens during creep,first towards the [001]-[111] boundary,and then to [001] or [111] along the boundary.Single slip and strong asymmetric deformation were observed during the first stage of lattice rotation in specimens with large misorientation.The rotation mechanism was associated with the activated slip systems according to the calculated Schmid factors.The impact of lattice rotation on the rupture properties was also discussed.

Solidification behavior of Re-and Ru-containing Ni-based single-crystal superalloys with thermal and metallographic analysis

To clarify the solidification behavior of Re- and Ru-containing Ni-based single-crystal superalloys, four experimental alloys with varied contents of Re and Ru were investigated by differential scanning calorimetry （DSC） and metallographic techniques. To obtain the - solvus temperatures, the stepwise solution and aging heat treatments were used. DSC analysis shows that Re leads to the increase in freezing range and γ-solvus temperature. On the contrast, Ru only has negligible influence on the freezing range, but leads to the lower γ-solvus temperature. In comparison with Ru, Re leads to more severe segregation and higher eutectic fractions in as-cast microstructures. Furthermore, the castability and phase stability of Ni-based superalloys were analyzed by the results of DSC and metallographic analysis, such as freezing range, critical nucleation temperature, γ-solvus temperature and eutectic fractions. It shows that Re leads to the wider freezing range and lower critical nucleation temperature, indicating the worse castability of Re-con- taining Ni-based single-crystal superalloys.

High-Temperature Structural Stabilities of Ni-Based SingleCrystal Superalloys Ni–Co–Cr–Mo–W–Al–Ti–Ta with Varying Co Contents

It has been recently pointed out that the compositions of industrial alloys are originated from cluster-plus-glueatom structure units in solid solutions. Specifically for Ni-based superalloys, after properly grouping the alloying elements into Al, Ni-like（Ni^-）, γ＇-forming Cr-like（Cr^-γ＇） and γ-forming Cr-like（Cr^-γ＇）, the optimal formula for single-crystal superalloys is established [Al–Ni^-12]（AlCr^-γ0：5Cr^-γ1：5）. The Co substitutions for Ni at the shell sites are conducted on the basis of the first-generation single-crystal superalloy AM3, formulated as [Al-Ni2-xCox]（Al1Ti0.25Ta0.25Cr1W0.25Mo0.25）, with x = 1.5, 1.75, 2 and 2.5（the corresponding weight percents of Co are 9.43, 11.0, 12.57 and 15.71, respectively）. The900 ℃ long-term aging follows the Lifshitz–Slyozov–Wagner theory（LSW theory）, and the Co content does not have noticeable influence on the coarsening rate of c0. The microstructure and creep behavior of the four（001） single-crystal alloys are investigated. The creep rupture lifetime is reduced as Co increases. The alloy with the lowest Co（9.43 Co） shows the longest lifetime of about 350 h at 1050 ℃/120 MPa, and all the samples show N-type rafting after creep tests.

镍基单晶高温合金近服役环境性能研究进展

航空发动机与燃气轮机作为国之重器,对保障国防安全和能源安全具有重要意义。随着发动机效率的不断提升,涡轮进气口温度不断提高。先进叶片往往采用高代次单晶高温合金材料制备,具有薄壁、多孔复杂冷却结构,且表面涂覆先进涂层,因而先进单晶叶片结构越来越精细复杂,服役过程中叶片不同部位温度场、应力场分布变化更大,其损伤机制无法通过传统棒状试样的变形损伤机制完全体现。基于先进单晶叶片的结构特点及服役环境特点,综述了叶片结构(薄壁、气膜孔)、二次枝晶取向(二次取向)及先进涂层等单一因素及多因素耦合作用对单晶合金拉伸、蠕变及疲劳等典型性能的影响规律及损伤机理研究,并对镍基单晶高温合金近服役环境性能研究的发展方向进行展望。

混合钎料对镍基单晶高温合金大间隙钎焊接头组织和性能的影响

【目的】采用一种新型镍基钎料和母材成分一致的高熔点合金粉混合的方法制备出混合钎料,研究了添加的高熔点合金粉的粒径和配比对钎缝微观组织和力学性能的影响。【方法】采用扫描电子显微镜对钎焊接头的析出相、元素分布、微观组织进行了分析,并对钎焊接头的硬度及持久性能进行了测试。【结果】研究表明,接头主要由钎料合金区(FAZ)、界面连接区(IBZ)和扩散影响区(DAZ)三部分组成。钎料合金区主要由M3B2和M8B型硼化物及γ/γ′相组成。界面连接区由γ和γ′沉淀强化相组成。当合金粉粒径为44μm和75μm时,均可得到无缺陷的焊接接头;但当合金粉粒径尺寸达177μm时,钎缝内会形成孔洞缺陷。【结论】随着合金粉比例的提高,接头连接区的显微硬度有所上升。当合金配比由30%到50%,接头的持久寿命由15 h增加至34 h;但进一步提升比例至60%时,接头的持久寿命下降至0.6 h。该文的结果可为实现高温热端零部件的连接和修复工程应用提供理论依据和参考价值。

基于机器学习的镍基单晶高温合金蠕变寿命预测模型研究

构建合适的镍基单晶合金蠕变寿命预测模型,对于我国航空发动机叶片设计、强度分析和寿命预测具有重要意义。采用多项式回归、最近邻回归、支持向量机回归、决策树回归四种机器学习算法,建立镍基单晶高温合金蠕变寿命与合金成分、微观组织和蠕变工艺参数的关系模型,为镍基单晶高温合金的蠕变性能调控提供了新方法。基于蠕变寿命预测模型,系统地比较了四种算法和特征选择对模型性能的影响。结果表明,支持向量机回归模型的预测结果最优,相关性较高的四个特征依次为γ′固溶温度、Ta、W、Re。研究结果可为获得更有效的镍基单晶高温合金蠕变性能预测方法提供参考。