ADVANCES IN SOLIDIFICATION CHARACTERISTICS AND TYPICAL CASTING DEFECTS IN NICKEL-BASED SINGLE CRYSTAL SUPERALLOYS

doi:10.11900/0412.1961.2015.00448

Acta Metall Sin

2015, Vol. 51

Issue (10): 1163-1178 DOI: 10.11900/0412.1961.2015.00448

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ADVANCES IN SOLIDIFICATION CHARACTERISTICS AND TYPICAL CASTING DEFECTS IN NICKEL-BASED SINGLE CRYSTAL SUPERALLOYS

Jun ZHANG(

),Taiwen HUANG,Lin LIU,Hengzhi FU

State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi'an 710072

Cite this article:

Jun ZHANG,Taiwen HUANG,Lin LIU,Hengzhi FU. ADVANCES IN SOLIDIFICATION CHARACTERISTICS AND TYPICAL CASTING DEFECTS IN NICKEL-BASED SINGLE CRYSTAL SUPERALLOYS. Acta Metall Sin, 2015, 51(10): 1163-1178.

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Abstract

Single crystal (SC) superalloy is a kind of complex structure and multi phase materials. With the increase of the degree of alloying and the content of refractory elements, or the more complicated structure and larger size of the casting made of SC superalloy, it is essential important to suppress the formation of solidification defects to improve the quality and performance of the blades. The microstructure and solidification defects of single crystal alloy are not only related to the composition of the alloy, but also depend on its solidification characteristics and technological conditions. The paper first summarizes the research progress of the solidification characteristics for advanced SC superalloys, focusing on analysis of the effects of solidification characteristics and processing parameters on the formation and its mechanics for two typical directional solidification defects, crystallographic orientation deviation and stray grains. Then some methods and approaches to suppress such defect formation for complex single crystal blade have been reviewed.

Key words: single crystal superalloy solidification characteristic solidification defect

Fund: Supported by National High Technology Research and Development Program of China (No.2012AA03A511), National Natural Science Foundation of China (Nos.51331005 and 50931004), National Basic Research Program of China (No.2011CB610406) and NPU Foundation for Fundamental Research (No.2014JM62270)

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	Jun ZHANG
	Taiwen HUANG
	Lin LIU
	Hengzhi FU

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https://www.ams.org.cn/EN/10.11900/0412.1961.2015.00448 OR https://www.ams.org.cn/EN/Y2015/V51/I10/1163

Fig.1 Effect of constituent level on liquidus temperature for Ru-containing multicomponent Ni-based superalloys^[12]

Fig.2 Characteristic temperatures for single crystal superalloys with varied contents of Re (a) and Ru (b) (T_L—liquidus temperature, T_S—solidus temperature, T_solvus—γ’ solvus temperature, T’—critical nucleation undercooling)^[15]

Table 1 Effect of carbon content on phase transformation temperature for AM3 alloy^[19]

Fig.3 Effects of Re and Ru on the eutectic fractions of as-cast alloys^[15]

Fig.4 DTA curves of one third generation single crystal superalloy at superheating temperatures of 1450 ℃ (a), 1550 ℃ (b), 1580 ℃ (c), 1650 ℃ (d), 1700 ℃ (e) and 1780 ℃ (f)^[25]

Fig.5 Effects of superheating temperature (a) and superheating time (b) on the partition coefficient K of the constituent elements in alloy DD90

Fig.6 Schematic of different solidification defects in single crystal turbine blade, modified from reference [26](LAB—low angle grain boundary, HAB—high angle grain boundary, RX grains—recrystallized grains, GS failure—grain selector failure)

Fig.7 Relationship between grain orientation deviation and initial height of the starter block^[28]

Fig.8 Rlationship between the geometry of starter block and the single crystal orientation (d—diameter, h—height of starter block)^[31]

Fig.9 Effects of withdrawal rate (a) and ceramic mould temperature (b) on the crystallographic orientation^[28]

Fig.10 Schematic of the casting for "seeding+seletor" processing (a), macrostructures of section of helical selector (b) and the seed (c) (pulling rate V=100 mm/s)^[34]

Fig.11 Schematic of dendritic growth of a single crystal in the presence of a cross-section enlargement^[38]

Table 2. Comparison of dendritic orientation in spiral grain selector of outlet and in seed^[34]

Fig.12 Simulation results of temperature field distribution in the blade platform at t=1740 s (a), t=1742 s (b) and t=1770 s (c), and schematic showing the liquidius isothermal in platform (d)^[34]

Fig.13 Photograph of blade model at platform after macrocorrosion for alloy 1-1 (a), alloy 1-2 (b), alloy 2-1 (c), alloy 2-2 (d), alloy 3-1 (e), alloy 3-2 (f) and sampling position (g) (V=100 mm/s)^[37]

Fig.14 Transverse section microstructure of platform in blade mode (a) by high rate solidification (HRS) method (b1~b4) and liquid meter cooling (LMC) method (b5~b8) at growth speeds of 3 mm/min (b1, b5), 4.5 mm/min (b2, b6), 6 mm/min (b3, b7) and 9 mm/min (b4, b8)^[48]

Table 3 Nominal composition of alloys used for studying the effect of composition change of Re, C and B on the formation of stray crystal in platform^[37]

Fig.15 Effect of graphite block on the formation of stray grain (V=9 mm/min)^[49]

Fig.16 CAFÉ (a) and experimental (b, c) results of single crystal superalloy blade model with grain continuator^[49]

Fig.17 Schematic diagrams showing the layouts (a) of seeds in samples in ways of q₁=0°, q₂=0° (b), q₁=15°, q₂=0° (c), q₁=0°, q₂=15° (d), q₁=0°, q₂=30° (e) and q₁=0°, q₂=45° (f) (V=100 mm/s)^[34]

Fig.18 Relationship between the deviation of secondary dendritic and misorientational angle^[34]

Fig.19 Diagrams showing stray grains in seed section and helical selector section (V=100 mm/s)^[34]
(a) seed and helical selector section of a casting macroetched to show the stray grains
(1) macrostructure at area 1 (2) macrostructure at area 2
(I) microstructure at location I (II) microstructure at location II (III) microstructure at location III
(b) EBSD inverse poles figures at location II
(c) EBSD inverse poles figures at location III

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