Recent Progress in Research and Development of Nickel-Based Single Crystal Superalloys

doi:10.11900/0412.1961.2019.00122

Acta Metall Sin

2019, Vol. 55

Issue (9): 1077-1094 DOI: 10.11900/0412.1961.2019.00122

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Recent Progress in Research and Development of Nickel-Based Single Crystal Superalloys

ZHANG Jian(

),WANG Li,WANG Dong,XIE Guang,LU Yuzhang,SHEN Jian,LOU Langhong

Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

Cite this article:

ZHANG Jian,WANG Li,WANG Dong,XIE Guang,LU Yuzhang,SHEN Jian,LOU Langhong. Recent Progress in Research and Development of Nickel-Based Single Crystal Superalloys. Acta Metall Sin, 2019, 55(9): 1077-1094.

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Abstract

Single crystal superalloy is the key material used in the hot section of aeroengines and industry gas turbines. The research, development and application of these alloys is generally a mirror of the industry base of a country. The recent progress in research and development of single crystal superalloys is briefly reviewed in the present paper. Some new ideas in alloy development and the design methods are summarized. The deformation behaviors, damage and failure mechanisms of single crystal superalloys during creep, fatigue, oxidation and hot corrosion have been overviewed. The role of typical defects such as low angle grain boundary, recrystallization and micro-porosity is also discussed. The recent progress in the directional solidification processes and typical parameters of high rate solidification, gas cooling casting, liquid metal cooling and fluidized bed cooling are introduced. Fundamental correlations of processing parameters to defect formation and microstructure evolution during manufacture of single crystal blade is discussed. Additionally, the future opportunities and challenges are also explored.

Key words: single crystal superalloy alloy design mechanical property directional solidification defect

Received: 22 April 2019

ZTFLH:

TG132.3

Fund: Supported by National Key Research and Development Program of China(No.2017YFB0702904);National Natural Science Foundation of China(Nos.91860201、51631008、51871210、51771204、U1732131和51671196);National Science and Technology Major Projects(Nos.2017-VII-0008-0101、2017-VI-0001-0070和2017-VI-0003-0073)

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	Jian ZHANG
	Li WANG
	Dong WANG
	Guang XIE
	Yuzhang LU
	Jian SHEN
	Langhong LOU

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https://www.ams.org.cn/EN/10.11900/0412.1961.2019.00122 OR https://www.ams.org.cn/EN/Y2019/V55/I9/1077

Fig.1 Creep rupture properties of Co-based alloys and the 1st generation Ni-based single crystal (SX) superalloys (T—temperature, K; t—time, h; P—Larson-Miller parameter)

Table 1 Design methods of single crystal superalloys

Alloys

Test condition

Creep mechanisms at intermediate temperature

Ref.

CMSX-4

1st generation SX alloy

750~850 ℃/450~750 MPa;

760 ℃/600, 700, 850 MPa

Different a/2<110> dislocations react at the interfaces of γ/γ'

a/2[011]+a/2[011]+a/2[ $1 ˉ$ 01]+a/2[ $1 ˉ$ 01]→a/3[112]+a/3[ $1 ˉ$ 12]+a/6[ $1 ˉ$ 12]+a/6[ $1 ˉ$ 12]a/3[ $1 ˉ$ 12] and a/6[ $1 ˉ$ 12] partial dislocations cut into γ' and leave a combination of SISF, SESF and APB

[33,34,38]

AM1, MC-NG, MC534, CMSX-10M, Rene N6

760 ℃/

840 MPa

a/2<110> dislocation cuts into γ' and results in a APB

[36]

SRR99

1st generation SX alloy

760 ℃/600, 780 MPa

760 ℃/600, 700, 850 MPa

a/2<110> dislocations dissociate at the interface:

a/2[ $1 ˉ$ 01]→a/3[ $1 ˉ$ $1 ˉ$ 2]+a/6[ $1 ˉ$ 2 $1 ˉ$ ]

a/3<112> partial dislocations cut into γ' and leave a SISF or SESF a/6<112> partial dislocation would be left at the γ/γ' interfaces

[37,38]

Table 2 Creep mechanisms at intermediate temperature^{[33,34,36,37,38]}

Fig.2 Creep rupture life of different single crystal superalloys

Fig.3 Rafted γ' (a) and dislocation networks (b) in a third generation single crystal superalloy DD33 creep ruptured at 1100 ℃ and 150 MPa^[47]

Fig.4 Typical defects observed in single crystal blade including low angle grain boundary (LAGB) (a), sliver (b), spurious grains (c), freckle (d), shrinkage (e) and recrystallization (RX) (f)

Table 3 Effect of minor elements on creep rupture life of bicrystals

Fig.5 RX layer formed at high temperature (a) and cellular RX formed at temperature below the solution temperature (b)

Fig.6 Effect of recrystallization on high temperature creep properties of DS and SX alloys

Fig.7 Micro-porosities in as cast (a) and as hot isostatically pressed (HIPed) (b) DD33 superalloy

Table 4 Comparison of several directional solidification processes

Fig.8 Typical configuration (a) and microstructures (b) of a spiral grain selector (h_s—length of screw pitch, d_s—diameter of spiral, θ—initial angle of spiral, d_w—diameter of helicoid)

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