Recent Progress in Research and Development of Nickel-Based Single Crystal Superalloys
ZHANG Jian1(), WANG Li1, XIE Guang1, WANG Dong1, SHEN Jian1, LU Yuzhang1, HUANG Yaqi1, LI Yawei1,2
1Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China 2School of Materials Science and Engineering, University of Science and Technology of China, Shenyang 110016, China
Cite this article:
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. Acta Metall Sin, 2023, 59(9): 1109-1124.
Single crystal Ni-based superalloys are key materials used in the hot section of aeroengines and industrial gas turbines. In service, single crystal blades face harsh environments, including high temperatures, complex stresses, oxidation and hot corrosion. Therefore, they must meet strict technical specifications, such as impurity, defects and dimensional control. Single crystal components should be manufactured using complex technologies within a highly narrow processing window. The present paper reviews recent progress in the research and development of alloy design, microstructure and property evolution and characterization, evaluation in near-service conditions, and single crystal manufacture. Further, the development of “next generation” high-temperature structural materials, such as refractory high-entropy alloys, is briefly discussed.
Fund: National Key Research and Development Program of China(2021YFB3702900);National Natural Science Foundation of China(5227-1042);National Natural Science Foundation of China(52071219);National Natural Science Foundation of China(52201151);National Natural Science Foundation of China(U2141206);National Natural Science Foundation of China(U2241283);National Science and Technology Major Project(P2022-C-IV-001-001);National Science and Technology Major Project(P2021-AB-IV-001-002);National Science and Technology Major Project(J2019-IV-0006-0074);National Science and Technology Major Project(J2019-VI-0010-0124);Directional Institutionalized Scientific Research Platform Relies on China Spallation Neutron Source of Chinese Academy of Sciences, International Partnership Program of Chinese Academy of Sciences(172GJHZ2022095FN);National Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology Harbin(JCKYS2022603C008)
Fig.1 Specific creep rupture life of different single crystal superalloys (P—Larson-Miller parameter, T—temperature (K), t—time, SX—single crystal superalloy)[3-10]
Fig.2 Schematics of temperature dependence of creep deformation mechanisms for single crystal superalloys (a-c) at medium temperature, the main deformation mechanism is matrix dislocation reaction (a), and at higher stress, dislocation dissociation is also activated (b), both mechanisms in Figs.2a and b lead to the formation of stacking faults (SFs) (c) (σ—applied stress) (d-f) at high temperature, the applied stress and misfit stress impel matrix dislocation reaction at γ/γ' interface during primary creep, and then dislocation networks generate (d), as creep in progress, high local stress and interaction of interfacial dislocations result in the formation of superdislocations, including a<110> type and a<100> type (e), the former is antiphase boundary (APB) coupled with dislocation pair, and the latter is dislocation pair with non-compact core originating from interfacial dislocations. In latter stage, γ'-raft cutting by superdislocations occurs (f)
DS process
Alloy
PDAS / μm
Volume fraction of porosity / %
Average porosity size / μm2
HRS
CMSX-4
333-384
0.072-0.102
18.9
FBC
CMSX-4
248-275
0.022-0.045
8.8
LMC
DD33
180
0.02
6.8
Table 1 Microstructures of single crystal castings obtained by high rate solidification (HRS), fluidized bed cooling (FBC), and liquid metal cooling (LMC)
Fig.3 Simulation of the temperature field during LMC process
Fig.4 Temperature dependence of compressive (a) and tensile (b) yield strengths of high-entropy alloys and superalloys[176~193] (Solid and hollow symbols in Fig.4a indicate single-phase and multi-phase alloys, respectively)
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