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.

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.

MICROMECHANICS OF THE DAMAGE-INDUCED CELLULAR MICROSTRUCTURE IN SINGLE CRYSTAL Ni-BASED SUPERALLOYS

An analytical method to investigate the morphological evolution of the cellular mi-crostructure is explored and proposed. The method is essentially based on the Es-helby 's micromechanics theory, and it is extended so as to be applied for a material system containing inclusions with high volume fraction, by employing the average stress field approximation by Mori and Tanaka. The proposed method enables us to discuss a stable shape of precipitate in the material system, which must be influenced by many factors: e.g., volume fraction of precipitate; Young's modulus ratio and lattice misfit between matrix and precipitate; external stress field in multiaxial state; and heterogeneity of plastic strain between matrix and precipitate. A series of numerical calculations were summarized on stable shape maps. The application of the method to predict the γ' rafting in superalloys during creep showed that the heterogeneity of plastic strain between matrix and precipitates may play a significant role in the shape stability of the precipitate. Furthermore, it was shown that the method was successfully applied to estimate the morphology of the cellular microstructure formed in CMSX-4 single crystal Ni-based superalloy.

Effects of directional solidification parameters and crystal selector on microstructure of single crystal of Ni-base superalloys

The single crystal of nickel-base super alloy is widely used for making turbine blades.The microstructure of the alloy,especially the deviation of preferred orientation of single crystal,possesses the most important effects on the mechanical properties of the blades.In this study,the single crystal ingot and blade of DZ417G alloy are prepared by means of the spiral crystal selector as well as the directional solidification method,and the effect of the parameters(i.e.,the shape of samples,the withdrawal rate)and the structure of the spiral crystal selector on the formation of single crystal and the crystal orientation are investigated.This method can prepare not only the single crystal ingot with simple shape but also the single crystal blades with the complex shape,the simple with rod-shape can form the single crystal easily with a relatively fast withdrawal rate,but the blade with complex shape requires much slower withdrawal rate to form single crystal.The length of the crystal selector almost has no effect on the crystal orientation.However,the angle of selector plays an obvious role on the orientation;the selector with a smaller angle can effectively reduce the deviation of preferred orientation;the appropriate angle of selector to obtain optimal orientation is found to be around30°and the deviation of preferred orientation is about30°for this selector.

Effect of carbon addition on carbide morphology of single crystal Ni-based superalloy

Single crystal superalloys of AM3 with different carbon levels were prepared at withdraw rate of 50μm/s. The effect of carbon addition on the carbide morphology was investigated. It was found that there were four types of MC-type carbides, acicular, nodular, blocky, and Chinese script-type in the crystals. With an increase in carbon level, the volume fraction of carbide increased significantly while the volume fraction of eutectic decreased significantly. Furthermore, the size of carbide in high level carbon alloy became much larger.

The ternary Ni–Al–Co embedded-atom-method potential for γ/γ Ni-based single-crystal superalloys: Construction and application

An Ni-AI-Co system embedded-atom-method potential is constructed for the γ（Ni）/γ＇（Ni3A1） superalloy based on experiments and first-principles calculations. The stacking fault energies （SFEs） of the Ni（Co, A1） random solid solutions are calculated as a function of the concentrations of Co and A1. The calculated SFEs decrease with increasing concentrations of Co and A1, which is consistent with the experimental results. The embedding energy term in the present potential has an important influence on the SFEs of the random solid solutions. The cross-slip processes of a screw dislocation in homogenous Ni（Co） solid solutions are simulated using the present potential and the nudged elastic band method. The cross-slip activation energies increase with increasing Co concentration, which implies that the creep resistance of γ（Ni） may be improved by the addition of Co.

Effect of solidification parameters on the microstructures of a single crystal Ni-based superalloy AM3

A single crystal Ni-based superalloy AM3 was processed at withdraw rates of 3.5, 10, 50, 100, 200, and 500 μm·s-1, respectively.The as-cast microstructures and solidification segregation ratio were characterized with various withdraw rates.The shape and size of carbide microstructures were determined.As expected, the primary and secondary dendrite arm spacings (PDAS and SDAS) decrease with the increase of withdraw rate.The highest volume fraction of eutectic γ/γ' is observed at the 100 μm·s-1 withdraw rate.The volume fraction of eutectic γ/γ' does not appear to be a strong function of the withdraw rate.With increasing withdraw rate, interface morphologies change in the sequence of planar, cellular, and dendrite.There is a general refinement of the microstructure as the withdraw rate increases.EPMA analysis showed that withdraw rate does not have obvious influence on the segregation of elements.

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.

Effect of solidification rate on MC-type carbide morphology in single crystal Ni-base superalloy AM3

In order to study the effect of the withdrawing rate on carbide morphology,MC-type carbide in single crystal superalloy AM3 was systematically investigated with sample growth rates from 3.5 μm/s to 500 μm/s.The carbide morphologies were investigated by scanning electron microscopy(SEM),and the electron probe microanalysis(EPMA) was used to characterize the carbide composition.The results indicate that the solidification rate is the important factor governing MC carbide growth morphology,size and distribution,composition and growth mechanism.With the increase of withdrawing rate,nodular,rod-like,Chinese script types of carbide morphology are observed.For the low withdrawing rate,with the increase of withdrawing rate,the carbide size becomes larger.For the case of dendritic interface,the carbide size becomes smaller with refinement of dendrites as withdrawing rate increases.The volume fraction of carbides increases with the withdrawing rate increasing.

Transient Liquid Phase Bonding of Ni-base Single Crystal Superalloy

The Ni-base single crystal superalloy was bonded by the transient liquid phase (TLP) bonding, using a Ni-base flexible metal cloth as an insert alloy. TLP bonding of superalloy was carried out at 1473-1523 K for 0.5-24 h in vacuum. The [001] orientation of each test specimen was aligned perpendicular to the joint interface. The bonded region was observed by optical microscopy, and the microstructural and compositional analyses across the bonded interlayer were performed by using a scanning electron microscopy (SEM). The electron back scattering diffraction (EBSD) method was applied to determine the crystallographic orientation. The results indicated that the chemical homogeneity across the bonded region can be achieved, and γ' phase both in the bonded interlayer and in the superalloy substrate is almost identical, while the bonded interlayer had almost matched the crystallographic orientation of the bonded substrates.

Effect of carbon additions on the microstructure of a single crystal Ni-based superalloy AM3

The microstructure of experimental nickel-base single crystal superalloys with different levels of carbon has been studied. The results indicated that with increasing carbon addition, the liquidus temperature decreased obviously and the as-cast microstructures exhibited a decrease in the amount of γ/γ′ eutectic structure and an increase in the volume fraction of carbides. The carbides formed in these alloys were most script-type MC carbides which appeared continuous dendritic networks in the interdendritic region. The segregation behavior of element W was influenced by the carbon addition.

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%.

Structural Dependence of Creep/Fatigue Behaviour of Single Crystal Ni-base Superalloy

The effect of different initial microstructures deftned by γ' precipitate morphology has been investigated at the creep/fatigue conditions of 900℃ and 500 MPa. The wave form of stress as a function of time for cyclic load was of trapezoidal shape with a hold time of 10s at the upper stress level. The TEM was employed to examine the deformation process in strengthened γ' matrix in dependence of γ' precipitate morphology. The fracture lifetime and cycle number up to fracture were the criteria to evaluate the additional cyclic component efFect on the course of deformation

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.

Molecular dynamics study of mosaic structure in the Ni-based single-crystal superalloy

The mosaic structure in a Ni-based single-crystal superalloy is simulated by molecular dynamics using a potential employed in a modified analytic embedded atom method. From the calculated results we find that a closed threedimensional misfit dislocation network, with index of （011）{100} and the side length of the mesh 89.6A, is formed around a cuboidal γ′ precipitate. Comparing the simulation results of the different mosaic models, we find that the side length of the mesh only depends on the lattice parameters of the γ and γ′ phases as well as the γ/γ′ interface direction, but is independent of the size and number of the cuboidal γ′ precipitate. The density of dislocations is inversely proportional to the size of the cuboidal γ′ precipitate, i.e. the amount of the dislocation is proportional to the total area of the γ/γ′ interface, which may be used to explain the relation between the amount of the fine γ′ particles and the creep rupture life of the superalloy. In addition, the closed three-dimensional networks assembled with the misfit dislocations can play a significant role in improving the mechanical properties of superalloys.

MC CARBIDE FLOATATION IN A HOT CORROSION RESISTANT SINGLE CRYSTAL Ni-BASE SUPERALLOY DURING DIRECTIONAL SOLIDIFICATION

The floating phenomenon of MC carbide(TiC)in a hot corrosion resistant single crystal Ni-base superalloy was observed during planar and cellular interface directional solidification.The explanation about the phenomenon is presented.

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.

TEM STUDY ON MICROSTRUCTURE OF LASERGLAZED SINGLE CRYSTAL Ni-BASE SUPERALLOY

The microstructure of a rapidly solidified single crystal Ni-base superalloy treated by laserglazing has been observed by TEM and STEM-EDAX techniques.Various morphologies of extraordinary flower-like MC carbide of TiC type were revealed in the nar- row interdendritic regions.While the superfine γ′ precipitate and higher density of dislocation were found in the γ matrix.

Temperature dependence of deformation mechanism in single crystal Ni-base superalloy

The tensile behavior of a new single crystal Ni-base superalloy was studied at various temperatures. Specimens were strained to fracture in the temperature range from 20℃ to 1000℃. σ0.2 is essentially unaffected by temperatures between 20℃ and 400℃. At higher temperatures it increases until it reaches a maximum at about 800℃. Beyond 800℃ a sharp decrease of strength is observed. There is a slight fluctuation in ductility between 20℃ and 800℃. The elongation to fracture increases from 10% to 36% as the temperature increases from 800℃ to 1000℃. The deformation is dominated by γ′ shearing and the high-density dislocations are observed in matrix channels at low temperatures. The dislocation microstructure is inhomogeneous due to the formation of dislocation concentrations with high-density tangling at intermediate temperatures. The networks deposited at the γ/γ′ interfaces prevent dislocations from entering the γ′ precipitates at high temperatures.

Effect of cobalt on chemical segregation and solution process in Re-containing single crystal superalloys

The effect of cobalt on chemical segregation and solution process in three nickel base single crystal superalloys was investigated. Three alloys containing the mass fraction of cobalt of 12% (named Alloy 1), 3% (named Alloy 2) and 0 (named Alloy 3), respectively were studied, in which the contents of other elements were same. The results show that the segregation extent of W, Re, Ta, Al between dendrite and interdendritic region rises with the increase of cobalt content. The incipient melting points decrease by 10℃and 20℃respectively when the content of cobalt increases from 0 through 3% to 12%. During solid solution at 1 340℃, the solid solution of large gamma prime in interdendritic region and the dissolution of eutectic in alloy 1 become easier than in other two alloys. After heat-treatment at 1 340℃for 8 h, the segregation extent of elements in alloy 1 decreases dramatically, while in alloy 2 and alloy 3, the segregation ratios decrease slowly. It suggests that the higher content of cobalt can accelerate the diffusion process at high temperature.