Effects of Processing on Microstructures and Properties of FGH4097 Superalloy

doi:10.11900/0412.1961.2021.00382

Acta Metall Sin

2022, Vol. 58

Issue (8): 992-1002 DOI: 10.11900/0412.1961.2021.00382

Research paper

Current Issue | Archive | Adv Search

Effects of Processing on Microstructures and Properties of FGH4097 Superalloy

XIE Leipeng, SUN Wenyao(

), CHEN Minghui(

), WANG Jinlong, WANG Fuhui

Shenyang National Laboratory for Materials Science, Northeastern University, Shenyang 110819, China

Cite this article:

XIE Leipeng, SUN Wenyao, CHEN Minghui, WANG Jinlong, WANG Fuhui. Effects of Processing on Microstructures and Properties of FGH4097 Superalloy. Acta Metall Sin, 2022, 58(8): 992-1002.

Download:

HTML

PDF(4301KB)
Export: BibTeX | EndNote (RIS)

Abstract

Powder metallurgy (PM) nickel-based superalloys are widely used as high-temperature, fatigue-resistant components in aircraft and gas turbines. However, many powder particle boundaries and carbides are found in alloys prepared via traditional methods, such as hot pressing (HP) and hot isostatic pressing, causing serious damage to the properties of PM superalloys. New methods and processes must be developed to improve the performance of PM superalloys. SEM, EBSD, and TEM were used in this work to investigate the microstructure, mechanical properties, and oxidation behavior of FGH4097 alloys prepared via spark plasma sintering (SPS) and HP. Owing to the advantages of uniform microstructure, fine grain, and less carbide precipitation, SPSed alloy has better tensile properties and oxidation resistance than HPed alloy. At 25^oC, SPSed alloy's yield, tensile strengths, and elongation are 998 MPa, 1401 MPa, and 17.1%, respectively; whereas those of HPed alloy are 951 MPa, 1262 MPa, and 14.4%, respectively. Although the two alloys exhibit similar yield and tensile strengths at 700^oC, SPSed alloy shows merely 80% higher ductility than HPed alloy. The oxidation mass gain of the two alloys oxidized at 900^oC for 100 h follows the parabolic law. A continuous and dense Al₂O₃ scale is formed on the surface of SPSed alloy, which effectively prevents the inward diffusion of O and outward diffusion of Cr and Ti. The mass gain is merely 0.19 mg/cm², and the oxidation rate is 1.03 × 10^-7 mg²/(cm⁴·s). Conversely, the oxidation rate of HPed alloy is approximately 2.6 times that of SPSed alloy. Severe internal oxidation occurs in HPed alloy, resulting in abundant less protective NiCr₂O₄ and TiO₂ formation on the surface, as well as large cracks and spalling.

Key words: FGH4097 superalloy microstructure mechanical property high temperature oxidation

Received: 06 September 2021

ZTFLH:

TG142.14

Fund: National Natural Science Foundation of China(51871051);Ministry of Industry and Information Technology Project(MJ-2017-J-99)

About author: SUN Wenyao, Tel: (024)83691562, E-mail: sunwenyao@mail.neu.edu.cnCHEN Minghui, professor, Tel: (024)83691562, E-mail: mhchen@mail.neu.edu.cn

	Service

	E-mail this article
	Add to citation manager
	E-mail Alert
	RSS
	（）
	Articles by authors
	Leipeng XIE
	Wenyao SUN
	Minghui CHEN
	Jinlong WANG
	Fuhui WANG

URL:

https://www.ams.org.cn/EN/10.11900/0412.1961.2021.00382 OR https://www.ams.org.cn/EN/Y2022/V58/I8/992

Fig.1 SEM image of FGH4097 pre-alloy powder (Inset shows the dendrite structure in powder)

Fig.2 Low (a, c) and high (b, d) magnified backscattered electron (BSE) images of FGH4097 alloys prepared by hot pressing (HP) (a, b) and spark plasma sintering (SPS) (c, d) (PPB—powder particle boundary)

Fig.3 BF-STEM images (a-d) of FGH4097 alloys prepared by HP (a, b) and SPS (c, d), and selected area electron diffraction (SAED) patterns for region 3 in Fig.3b (e) and region 5 in Fig.3c (f), respectively

Table 1 EDS results of regions 1-6 in Fig.3

Fig.4 EBSD images (a, c) and grain size distributions (b, d) of FGH4097 alloys prepared by HP (a, b) and SPS (c, d)

Fig.5 Engineering stress-strain curves of FGH4097 alloys prepared by HP and SPS
(a) 25^oC (b) 700^oC

Fig.6 Fracture surface (a, b) and cross-sectional (c-f) morphologies of FGH4097 alloys prepared by HP (a, c, e) and SPS (b, d, f) after tensile test at 25^oC (GB—grain boundary)

Fig.7 Isothermal oxidation kinetics of the FGH4097 alloys prepared by HP and SPS at 900^oC for 100 h (y—oxidation weight gain per unit area, t—oxidation time, k_p—rate constant of the parabola, y² = k_pt)
(a) y vs t (b) y²vs t

Fig.8 XRD spectra of FGH4097 alloys prepared by HP and SPS after oxidation at 900^oC for 100 h

Fig.9 Surface (a, b) and cross-sectional (c-f) SEM images of FGH4097 alloys prepared by HP (a, c, e) and SPS (b, d, f) after oxidation at 900^oC for 100 h

Table 2 Contributions of each strengthening mechanism to the yield strength of HPed and SPSed FGH4097 alloys

1	Backman D G, Williams J C. Advanced materials for aircraft engine applications [J]. Science, 1992, 255: 1082 pmid: 17817782
2	Reed R C. The Superalloys: Fundamentals and Applications [M]. London: Cambridge University Press, 2008: 33
3	Schafrik R, Sprague R. Superalloy technology: A perspective on critical innovations for turbine engines [J]. Key Eng. Mater., 2008, 380: 113 doi: 10.4028/www.scientific.net/KEM.380.113
4	Fecht H, Furrer D. Processing of nickel-base superalloys for turbine engine disc applications [J]. Adv. Eng. Mater., 2000, 2: 777 doi: 10.1002/1527-2648(200012)2:12<777::AID-ADEM777>3.0.CO;2-R
5	Liu F F, Chen J Y, Dong J X, et al. The hot deformation behaviors of coarse, fine and mixed grain for Udimet 720Li superalloy [J]. Mater. Sci. Eng., 2016, A651: 102
6	Zhang G Q, Zhang Y W, Zheng L, et al. Research progress in powder metallurgy superalloys and manufacturing technologies for aero-engine application [J]. Acta Metall. Sin., 2019, 55: 1133
	张国庆, 张义文, 郑亮等. 航空发动机用粉末高温合金及制备技术研究进展 [J]. 金属学报, 2019, 55: 1133
7	Raisson G. Evolution of PM nickel base superalloy processes and products [J]. Powder Metall., 2008, 51: 10 doi: 10.1179/174329008X286631
8	Qu X H, Zhang G Q, Zhang L, Applications of powder metallurgy technologies in aero-engines [J]. J. Aeronaut. Mater., 2014, 34(1): 1
	曲选辉, 张国庆, 章林. 粉末冶金技术在航空发动机中的应用 [J]. 航空材料学报, 2014, 34(1): 1
9	Miner R V, Gayda J. Effects of processing and microstructure on the fatigue behaviour of the nickel-base superalloy René 95 [J]. Int. J. Fatigue, 1984, 6: 189 doi: 10.1016/0142-1123(84)90037-9
10	Radavich J, Furrer D. Assessment of Russian P/M superalloy EP741NP [A]. Superalloys 2004 [C]. Pittsburgh: The Minerals, Metals & Materials Society, 2004: 381
11	Ma W B, Liu G Q, Hu B F, et al. Effect of Hf on carbides of FGH4096 superalloy produced by hot isostatic pressing [J]. Mater. Sci. Eng., 2013, A587: 313
12	Qiu C L, Attallah M M, Wu X H, et al. Influence of hot isostatic pressing temperature on microstructure and tensile properties of a nickel-based superalloy powder [J]. Mater. Sci. Eng., 2013, A564: 176
13	Roncery L M, Lopez-Galilea I, Ruttert B, et al. Influence of temperature, pressure, and cooling rate during hot isostatic pressing on the microstructure of an SX Ni-base superalloy [J]. Mater. Des., 2016, 97: 544 doi: 10.1016/j.matdes.2016.02.051
14	Khoshghadam-Pireyousefan M, Mohammadzadeh A, Heidarzadeh A, et al. Fundamentals of spark plasma sintering for metallic, ceramic, and polymer matrix composites production [J]. Encycl. Mater.: Compos., 2021, 2: 822
15	Guillon O, Gonzalez-Julian J, Dargatz B, et al. Field-assisted sintering technology/spark plasma sintering: Mechanisms, materials, and technology developments [J]. Adv. Eng. Mater., 2014, 16: 830 doi: 10.1002/adem.201300409
16	Yang W P, Liu G Q, Wu K, et al. Influence of sub-solvus solution heat treatment on γ′ morphological instability in a new Ni-Cr-Co-based powder metallurgy superalloy [J]. J. Alloys Compd., 2014, 582: 515 doi: 10.1016/j.jallcom.2013.07.045
17	Galindo-Nava E I, Connor L D, Rae C M F. On the prediction of the yield stress of unimodal and multimodal γ′ nickel-base superalloys [J]. Acta Mater., 2015, 98: 377 doi: 10.1016/j.actamat.2015.07.048
18	Wang L. Mechanical Properties of Materials [M]. 3rd Ed., Shenyang: Northeast University Press, 2014: 89
	王磊. 材料的力学性能 [M]. 第 3版, 东北大学出版社, 2014: 89
19	Thébaud L, Villechaise P, Crozet C, et al. Is there an optimal grain size for creep resistance in Ni-based disk superalloys? [J]. Mater. Sci. Eng., 2018, A716: 274
20	Kozar R W, Suzuki A, Milligan W W, et al. Strengthening mechanisms in polycrystalline multimodal nickel-base superalloys [J]. Metall. Mater. Trans., 2009, 40A: 1588
21	Roth H A, Davis C L, Thomson R C. Modeling solid solution strengthening in nickel alloys [J]. Metall. Mater. Trans., 1997, 28A: 1329
22	Dong X M, Zhang X L, Du K, et al. Microstructure of carbides at grain boundaries in nickel-based superalloys [J]. J. Mater. Sci. Technol., 2012, 28: 1031 doi: 10.1016/S1005-0302(12)60169-8
23	Sundararaman M, Mukhopadhyay P, Banerjee S. Carbide precipitation in nickel base superalloys 718 and 625 and their effect on mechanical properties [A]. Superalloys 718, 625, 706 and Various Derivatives [C]. Pittsburgh: The Minerals, Metals & Materials Society, 1997: 367
24	Sreenu B, Sarkar R, Kumar S S S, et al. Microstructure and mechanical behaviour of an advanced powder metallurgy nickel base superalloy processed through hot isostatic pressing route for aerospace applications [J]. Mater. Sci. Eng., 2020, A797: 140254
25	Pérez P, González-Carrasco J L, Adeva P. Influence of exposure time and grain size on the oxidation behaviour of a PM Ni₃Al alloy at 635^oC [J]. Corros. Sci., 1998, 40: 631 doi: 10.1016/S0010-938X(97)00166-2
26	Wang J L, Chen M H, Yang L L, et al. Nanocrystalline coatings on superalloys against high temperature oxidation: A review [J]. Corros. Commun., 2021, 1: 58 doi: 10.1016/j.corcom.2021.06.003
27	Zhao W, Gleeson B. Assessment of the detrimental effects of steam on Al₂O₃-scale establishment [J]. Oxid. Met., 2015, 83: 607 doi: 10.1007/s11085-015-9541-8
28	Sun W Y, Chen M H, Bao Z B, et al. Breakaway oxidation of a low-Al content nanocrystalline coating at 1000℃ [J]. Surf. Coat. Technol., 2019, 358: 958 doi: 10.1016/j.surfcoat.2018.12.034
29	Yang S S, Yang L L, Chen M H, et al. Understanding of failure mechanisms of the oxide scales formed on nanocrystalline coatings with different Al content during cyclic oxidation [J]. Acta Mater., 2021, 205: 116576 doi: 10.1016/j.actamat.2020.116576
30	Yu H, Ukai S, Hayashi S, et al. Effect of Al content on the high-temperature oxidation of Co-20Cr-(5, 10) Al oxide dispersion strengthened superalloys [J]. Corros. Sci., 2017, 118: 49 doi: 10.1016/j.corsci.2017.01.015
31	Guo C, Yu Z R, Liu C, et al. Effects of Y₂O₃ nanoparticles on the high-temperature oxidation behavior of IN738LC manufactured by laser powder bed fusion [J]. Corros. Sci., 2020, 171: 108715 doi: 10.1016/j.corsci.2020.108715

[1]	ZHANG Leilei, CHEN Jingyang, TANG Xin, XIAO Chengbo, ZHANG Mingjun, YANG Qing. Evolution of Microstructures and Mechanical Properties of K439B Superalloy During Long-Term Aging at 800^oC[J]. 金属学报, 2023, 59(9): 1253-1264.
[2]	LU Nannan, GUO Yimo, YANG Shulin, LIANG Jingjing, ZHOU Yizhou, SUN Xiaofeng, LI Jinguo. Formation Mechanisms of Hot Cracks in Laser Additive Repairing Single Crystal Superalloys[J]. 金属学报, 2023, 59(9): 1243-1252.
[3]	ZHENG Liang, ZHANG Qiang, LI Zhou, ZHANG Guoqing. Effects of Oxygen Increasing/Decreasing Processes on Surface Characteristics of Superalloy Powders and Properties of Their Bulk Alloy Counterparts: Powders Storage and Degassing[J]. 金属学报, 2023, 59(9): 1265-1278.
[4]	GONG Shengkai, LIU Yuan, GENG Lilun, RU Yi, ZHAO Wenyue, PEI Yanling, LI Shusuo. Advances in the Regulation and Interfacial Behavior of Coatings/Superalloys[J]. 金属学报, 2023, 59(9): 1097-1108.
[5]	ZHANG Jian, WANG Li, XIE Guang, WANG Dong, SHEN Jian, LU Yuzhang, HUANG Yaqi, LI Yawei. Recent Progress in Research and Development of Nickel-Based Single Crystal Superalloys[J]. 金属学报, 2023, 59(9): 1109-1124.
[6]	WANG Lei, LIU Mengya, LIU Yang, SONG Xiu, MENG Fanqiang. Research Progress on Surface Impact Strengthening Mechanisms and Application of Nickel-Based Superalloys[J]. 金属学报, 2023, 59(9): 1173-1189.
[7]	LIU Xingjun, WEI Zhenbang, LU Yong, HAN Jiajia, SHI Rongpei, WANG Cuiping. Progress on the Diffusion Kinetics of Novel Co-based and Nb-Si-based Superalloys[J]. 金属学报, 2023, 59(8): 969-985.
[8]	LI Jingren, XIE Dongsheng, ZHANG Dongdong, XIE Hongbo, PAN Hucheng, REN Yuping, QIN Gaowu. Microstructure Evolution Mechanism of New Low-Alloyed High-Strength Mg-0.2Ce-0.2Ca Alloy During Extrusion[J]. 金属学报, 2023, 59(8): 1087-1096.
[9]	DING Hua, ZHANG Yu, CAI Minghui, TANG Zhengyou. Research Progress and Prospects of Austenite-Based Fe-Mn-Al-C Lightweight Steels[J]. 金属学报, 2023, 59(8): 1027-1041.
[10]	CHEN Liqing, LI Xing, ZHAO Yang, WANG Shuai, FENG Yang. Overview of Research and Development of High-Manganese Damping Steel with Integrated Structure and Function[J]. 金属学报, 2023, 59(8): 1015-1026.
[11]	SUN Rongrong, YAO Meiyi, WANG Haoyu, ZHANG Wenhuai, HU Lijuan, QIU Yunlong, LIN Xiaodong, XIE Yaoping, YANG Jian, DONG Jianxin, CHENG Guoguang. High-Temperature Steam Oxidation Behavior of Fe22Cr5Al3Mo-xY Alloy Under Simulated LOCA Condition[J]. 金属学报, 2023, 59(7): 915-925.
[12]	YUAN Jianghuai, WANG Zhenyu, MA Guanshui, ZHOU Guangxue, CHENG Xiaoying, WANG Aiying. Effect of Phase-Structure Evolution on Mechanical Properties of Cr₂AlC Coating[J]. 金属学报, 2023, 59(7): 961-968.
[13]	GUO Fu, DU Yihui, JI Xiaoliang, WANG Yishu. Recent Progress on Thermo-Mechanical Reliability of Sn-Based Alloys and Composite Solder for Microelectronic Interconnection[J]. 金属学报, 2023, 59(6): 744-756.
[14]	ZHANG Deyin, HAO Xu, JIA Baorui, WU Haoyang, QIN Mingli, QU Xuanhui. Effects of Y₂O₃ Content on Properties of Fe-Y₂O₃ Nanocomposite Powders Synthesized by a Combustion-Based Route[J]. 金属学报, 2023, 59(6): 757-766.
[15]	WU Dongjiang, LIU Dehua, ZHANG Ziao, ZHANG Yilun, NIU Fangyong, MA Guangyi. Microstructure and Mechanical Properties of 2024 Aluminum Alloy Prepared by Wire Arc Additive Manufacturing[J]. 金属学报, 2023, 59(6): 767-776.

No Suggested Reading articles found!

Viewed

Full text

Abstract

Cited

Shared

Discussed