Recent Progress in Alloy Design and Creep Mechanism of γ'-Strengthened Co-Based Superalloys

doi:10.11900/0412.1961.2023.00223

Acta Metall Sin

2023, Vol. 59

Issue (9): 1125-1143 DOI: 10.11900/0412.1961.2023.00223

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Recent Progress in Alloy Design and Creep Mechanism of γ'-Strengthened Co-Based Superalloys

FENG Qiang¹(

), LU Song¹, LI Wendao¹^,², ZHANG Xiaorui¹, LI Longfei¹(

), ZOU Min¹, ZHUANG Xiaoli¹

¹Beijing Innovation Center for Materials Genome Engineering, State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Beijing 100083, China
²School of Materials Science and Engineering, Xiangtan University, Xiangtan 411105, China

Cite this article:

FENG Qiang, LU Song, LI Wendao, ZHANG Xiaorui, LI Longfei, ZOU Min, ZHUANG Xiaoli. Recent Progress in Alloy Design and Creep Mechanism of γ'-Strengthened Co-Based Superalloys. Acta Metall Sin, 2023, 59(9): 1125-1143.

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Abstract

Recently, with the development of aviation engines and ground-based gas turbines, the demands for the environmental resistance and temperature-bearing capacity of their key hot-end components have considerably increased. Compared to Ni-based superalloys, novel γ′-strengthened Co-based superalloys are more advantageous owing to their corrosion resistance and melting temperature. To facilitate the development of these alloys, research on their alloying principles, alloy design, and creep mechanisms is summarized in this paper based on domestic and international results. Furthermore, herein, the key scientific problems in the development of such alloys are discussed, and the possible development trends and challenges in the future are surveyed.

Key words: Co-based superalloy γ'-strengthened alloying alloy design creep

Received: 18 May 2023

ZTFLH:

TG132.3

Fund: National Natural Science Foundation of China(52171095);National Natural Science Foundation of China(52201100);National Natural Science Foundation of China(52201024);National Natural Science Foundation of China(51771019);National Natural Science Foundation of China(92060113);National Key Research and Development Program of China(2017YFB0702902);China Postdoctoral Science Foundation(2022M710346)

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	FENG Qiang
	LU Song
	LI Wendao
	ZHANG Xiaorui
	LI Longfei
	ZOU Min
	ZHUANG Xiaoli

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https://www.ams.org.cn/EN/10.11900/0412.1961.2023.00223 OR https://www.ams.org.cn/EN/Y2023/V59/I9/1125

Table 1 Typical elements and their effect on the γ'-strengthened Co-based superalloys

Fig.1 Effects of temperature (T) on lattice misfit (δ) in γ'-strengthened Co-based (a)^[15] and Ni-based (b)^[23] superalloys (a_γ —lattice constant of γ phase, a_γ' —lattice constant of γ' phase)

Fig.2 Elemental partitioning between γ and γ' phases in a γ'-strengthened Co-based superalloy^[26] (HAADF—high-angle annular dark field)

Table 2 Nominal compositions and γ' solvus temperature (T_γ'_-solvus) of some γ'-strengthened Co-based superalloys^{[1,6,7,10,11,13,21,25,32-42]}

Fig.3 Mean diffusion coefficients ( $D ¯$ ) of some alloying elements of fourth (a) and fifth (b) period in Co and Ni^[47]

Fig.4 Schematics of alloy design for multi-component Co-based superalloys based on multicomponent diffusion-multiple^[5,26]

Fig.5 Creep properties of γ′-strengthened Co (Co-Al-W/CoNi)- and Ni-based single crystal superalloys^{[12,13,90,93,95,96]} (T—temperature (K), t_r—rupture life (h))

Fig.6 Effect of Ti and Ta elements on creep properties of Co-Al-W-based single crystal superalloys^[13]

Fig.7 Microstructural evolutions during the tensile creep process of a Co-Al-W-based single crystal superalloys with the positive misfit at 900^oC and 420 MPa^[98] (Insets show the γ/γ' microstructures during the creep process, and the red circles indicate the topological inversed microstructure. σ—stress)

Fig.8 Atomic structures of superlattice intrinsic stacking fault (SISF) (a)^[102] and superlattice extrinsic stacking fault (SESF) (b)^[91] in the γ' phase as well as their schematic formation mechanisms (c) in γ'-strengthened Co-based single crystal superalloys (Inset in Fig.8a shows a center-of-symmetry map of the structure. LPD—leading partial dislocation, ISF—intrinsic stacking fault, APB—antiphase boundary, CISF—complex intrinsic stacking fault)

Fig.9 Different types of stacking fault (SF) interaction configurations in Co-Al-W-based single crystal superalloys^[91]
(a) TEM image
(b-d) atomic resolution HAADF-scanning transmission electron microscopy (HAADF-STEM) images of V-type (b), T-type (c), and X-type (d) (Inset in Fig.9c shows an enlarged view of the red square, indicating a deviation between the SISF-2 and SISF-2′ planes)

Fig.10 Formation mechanism of APB-SISF-APB configuration in CoNi-based single crystal superalloys^[28] ((1) two closely spaced Shockley partials approach the γ' phase on the (111) glide plane. (2) the leading partial enters the γ' phase, forming a SISF. (3) the trailing partial also enters the γ' phase, transforming the SISF into an APB. (4) the leading partial shears through the entire γ' phase, and the trailing partial forms a closed loop inside the γ' phase. (5) both of leading and trailing partials shear through the entire γ' phase, and partial dislocation loop surrounds an SISF and is embedded in an APB. The bottom-right corner right shows the corresponding dislocation schematic of SISF→APB transformation in the γ' phase. a—lattice constant of γ' phase, F_L—dislocation line tension, F_τ —glide force resulting from the resolved shear stress, F_f—net force originating from difference between the APB and SISF energies, b_APB—Burgers vector of APB, b_SISF—Burgers vector of SISF)

Fig.11 Schematic representations of the evolution of the γ/γ' microstructure and dislocation substructure in a γ'-strengthened Co-based single crystal superalloy during the deceleration (a), the minimum stable (b), onset of the global stable (c), near the end of the global stable (d), and the acceleration tensile creep (e) stages^[90]

Fig.12 Influence of alloying elements on the SF (Co₃TM) (a)^[107]and APB (Co₃Al_0.75TM_0.25) (b)^[108] energies of γ' phase (ANNI—axial nearest-neighbor Ising, γ_APB—APB energy, FP—first-principles calculation, Exp.—experiment)

Fig.13 Segregation-assisted transformation from complex stacking faults (CSFs) to superlattice stacking faults (SSFs) (a)^[111] and SISF bounding by a Shockley partial dislocation in the γ' phase (b)^[104] (CESF—complex extrinsic stacking fault, Inset in Fig.13b shows the Burgers vector ( b ) obtained from the Burgers circuit analysis)

Fig.14 Segregation-assisted γ'→γ transformation in the γ'-strengthened Co-based single crystal superalloys (Insets show the fast Fourier transform (FFT) spectra confirming the ordered and disordered structure in the γ' and γ' regions)
(a) leading partial dislocation in a Co-Al-W-based single crystal superalloy^[104]
(b) SF interaction in a CoNi-based single crystal superalloy^[94]

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