Effect of Gravity on Directionally Solidified Structure of Superalloys
MA Dexin1,2(), ZHAO Yunxing1,2, XU Weitai1, WANG Fu3
1Shenzhen Wedge Central South Research Institute Co. Ltd., Shenzhen 518045, China 2Powder Metallurgy Research Institute, Central South University, Changsha 410083, China 3School of Mechanical and Electrical Engineering, Xi'an Jiaotong University, Xi'an 710049, China
Cite this article:
MA Dexin, ZHAO Yunxing, XU Weitai, WANG Fu. Effect of Gravity on Directionally Solidified Structure of Superalloys. Acta Metall Sin, 2023, 59(9): 1279-1290.
While using traditional methods of directionally solidifying superalloy castings, the liquid density at the lower region of the mushy zone gradually lowers than the top. This is due to a strong segregation of alloying elements. The gravitational force then exacerbates this density inversion, leading to upward convection from the mushy zone to the liquid ahead of the solidification front. This process, known as solutal convection, results in several solidification defects such as freckle defects, an upward accumulation of γ/γ' eutectic, and seeding process issues. As higher-generation single crystal superalloys continue to develop, the problems of element segregation and solutal convection become more pronounced. Traditional measures, such as adjusting process parameters, struggle to effectively alleviate these issues. Given that these problems largely arise from gravity-induced fluid flow, this work aims to investigate the role of gravity on solidification structure and propose appropriate solutions. To achieve this, the conventional pull-down and novel pull-up methods were adopted to perform directional solidification experiments with superalloys. The influence of gravity on solidification behavior is starkly different in these two experiments. In the pull-down process, dendrites grow upward, against gravity, leading to a variety of solidification defects such as freckles on the casting's lateral surface and an upward accumulation of γ/γ' eutectic on the upper surface of the single crystal turbine blade castings. Stray grains also formed in the remelting region during seeding. These phenomena are caused by the density inversion of the remaining liquid between dendrites, resulting in a top-heavy and bottom-light hydrodynamic state. Liquid convection in the mushy zone was then unavoidable under gravity in the pull-down process. In contrast, the pull-up process had dendrites growing downwards, in line with gravity, leaving the least dense liquid at the top of the mushy zone. In this top-light and bottom-heavy state, gravity stabilizes the segregated residual liquid in the mushy zone, thereby preventing solutal convection. Consequently, freckle defects were eliminated, and the γ/γ' eutectic structure was evenly distributed, not accumulated, on the upper surface of the single crystal blade's platform. Additionally, the stability of remelting and epitaxial growth of seed crystals was ensured by eliminating liquid convection. By using this pull-up process, the negative effects of gravity on the directional solidification of superalloys were removed, and all gravity-related solidification defects consequently disappeared. This novel pull-up process could potentially be developed into a new production process for single crystal superalloy castings, significantly improving casting quality. However, it should be noted that this new pull-up process is more complex in comparison to the conventional method. Although this work lays the groundwork for this process, further technological enhancements are required before this method can be applied to industrial production.
Table 1 Compositions and densities of the selected Ni-based superalloys
Fig.1 Schematics of directional solidification in different directions using pull-down (a) and pull-up (b) methods, resulting in upward solidification (UWS) and downward solidification (DWS), respectively
Fig.2 Etched surface photos (a1-a3) and corresponding cross-section OM images (b1-b3) of three CMSX-4 alloy samples with circular (a1, b1), square (a2, b2), and cross shaped (a3, b3) cross-sections prepared by the pull-down method (Ellipse zones in Figs.1b1-b3 show the freckles)
Fig.3 Etched surface photos (a1-a3) and corresponding cross-section OM images (b1-b3) of three CMSX-4 alloy samples with circular (a1, b1), square (a2, b2), and cross shaped (a3, b3) cross-sections prepared by the pull-up method
Fig.4 Schematics of UWS (a) and DWS (b)
Fig.5 Partial photo of a CMSX-4 blade casting prepared by pull-down method (a), and longitudinal section OM images of platform in as-cast (b1) and heat treated (b2) states
Fig.6 Cross-section OM images near the top (a1, b1) and bottom (a2, b2) surfaces of the platform in as-cast (a1, a2) and heat treated (b1, b2) states for CMSX-4 blade prepared by pull-down method
Fig.7 Longitudinal section OM images of platform in as-cast (a) and heat treated (b) states for CMSX-4 blade prepared by pull-up method
Fig.8 Cross-section OM images near the top (a1, b1) and bottom (a2, b2) surfaces of the platform in as-cast (a1, a2) and heat treated (b1, b2) states for CMSX-4 blade prepared by pull-up method
Fig.9 Schematics of dendrite and γ/γ' eutectic growth in platform during UWS (a) starting stage (b) stable growth stage (c) end stage
Fig.10 Schematics of dendrite and γ/γ' eutectic growth in platform during DWS (a) starting stage (b) stable growth stage (c) end stage
Fig.11 Longitudinal section OM images near the remelting zone showing the structure transition from CMSX-6 seed to CMSX-4 prepared by pull-down (a) and pull-up (b) methods
Fig.12 Longitudinal section OM images near the remelting zone showing the structure transition from CM247 seed to CMSX-4 prepared by pull-down (a) and pull-up (b) methods
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