High temperature creep mechanisms of a single crystal superalloy: A phasefield simulation and microstructure characterization

The high temperature creep behavior of a single crystal Ni-based superalloy was studied by combined experimental and numerical methods. The creep test results showed that the creep curves exhibited a three-stage feature. The qualitative explanations for each stage of the creep curves were carried out based on the microstructure characterizations of γ/γ′ phases and dislocations. An elastoplasticity incorporated phase-field model was developed to provide quantitative understanding on directional coarsening(rafting) of γ′ phase. The simulation results showed that the directionality of γ′ coarsening was induced by both dislocation activity in γchannels and elastic inhomogeneity between γ and γ' phases, therein the dislocation activity played a major role.This findings provide new insights into the design of novel single crystal superalloys with improved creep properties.     

Dendrite morphology and evolution mechanism of nickel-based single crystal superalloys grown along the o0014 and o0114 orientations

Nickel-based single crystal superalloys oriented along the o0014 and o0114 lattice directions were produced by a bottom seeding technique in an attempt to understand the evolution mechanism of the dendrite grown along different orientations in the present study. The changes in primary dendrite arm spacing for single crystal with different orientations are also discussed. It was found that the dendrite morphologies of single crystal superalloy grown along o0114 were different from that of o0014. Firstly, the dendrites showed the irregular cruciforms and array in rows in a transverse section. Secondly, no typical primary dendrites were observed but the dendrite morphologies appeared like the letter ‘‘V’’ or ‘‘W’’ in a longitudinal section. The primary dendrite arms grew along the o0014 orientation from the bottom of the sample in the o0014 orientation. However, in the o0114 orientation, the single crystal developed by continuous side-branching along the [001] and [010] orientations. The primary dendrite arm spacing was as the function of the deviation angle f. It indicates that with the increase in the deviation angle f, the primary dendrite arm spacing first increased, and then decreased.     

Effect of the withdrawal rate on the microstructure and thermal durability of a third-generation single crystal superalloy

Single crystal Ni-based superalloys are the typical structural materials for high-pressure turbine blades, and their microstructure is critical in determining their mechanical properties. The withdrawal rate is a key parameter affecting the microstructure during the single crystal growth process. In the present work the effect of the withdrawal rate on the microstructure of a third-generation single crystal superalloy containing 6.8 ?wt% Re has been investigated, and the creep resistance of the alloy determined. The results showed that increased withdrawal rate refined the dendritic structure, reduced dendritic arm spacing, promoted the growth of secondary tertiary dendrites and decreased solidification segregation with a reduced size of γ′ phase. The porosity density of the as-cast alloy first decreased and then increased with the withdrawal rate, while the minimum porosity densityoccurred when the alloy was under the solidification condition of withdrawal rate of 4.5 ?mm/min. The maximum creep rupture life of 326.4 ?h of the heat-treated alloys under the test condition of 1100 ?°C/140 ?MPa also appeared at the alloys under the withdrawal rates of 4.5 ?mm/min. It is believed that the minimum porosity density and reduced size of the γ′ phase may be the main reasons for the enhanced creep rupture life of the alloys with withdrawal rates of 4.5 ?mm/min. This investigation provides theoretical support and a practical basis for the development of third-generation single crystal superalloys.     

定向凝固技术制取高温合金单晶铸件的思考

回顾了单晶高温合金的发展历史，结合晶体学知识系统总结与分析了制取高温合金单晶的两种定向凝固技术的原理与晶体竞争生长机制．对两种方法现有工艺的优缺点进行了深入思考与比较，提出了两种制取任何所希望取向理想单晶的新方法，旨在为完善单晶高温合金的制取工艺提供新思路．     

Microstructure and stress rupture properties of polycrystal and directionally solidified castings of nickel-based superalloys

A new directionally solidified Ni-based superalloy DZ24, which is a modification of K24 alloy without rare and expensive elemental additions, such as Ta and Hf, was studied in this paper. The microstructure and stress rupture properties of conventionally cast and directionally solidified superalloys were comparatively analyzed. It is indicated that the microstructure of K24 alloy is composed of γ, γ′, γ/γ′ eutectics and MC carbides. Compared with the microstructure of K24 polycrystalline alloy, γ/γ′ eutectic completely dissolves into the γ matrix, the fine and regular γ′ phase reprecipitates, and MC carbides decompose to M₆C/M₂₃C₆ carbides after heat treatment in DZ24 alloy. The rupture life of DZ24 alloy is two times longer than that of K24 alloy. The more homogeneous the size of γ′ precipitate, the longer the rupture life. The coarsening and rafting behaviors of γ′ precipitates are observed in DZ24 alloy after the stress-rupture test.     

Effects of Ru on the microstructure and phase stability of a single crystal superalloy

Two experimental single crystal superalloys, the Ru-free alloy and the Ru-containing alloy with[001] orientation, were cast in a directionally solidified furnace, while other alloying element contents were kept unchanged. The effects of Ru on the microstructure and phase stability of the single crystal superalloy were investigated. γ' directional coarsening and rafting were observed in the Ru-free alloy and Ru-containing alloy after long-term aging at 1070℃ for 800 h. Needle-shaped σ topologically close packed (TCP) phases precipitated and grew along the fixed direction in both the alloys. The precipitating rate and volume fraction of TCP phases decreased significantly by adding Ru. The compositions of γ and γ' phases measured using an energy-dispersive X-ray spectroscope (EDS) in transmission electron microscopy (TEM) analysis showed that the addition of Ru lessened the partition ratio of TCP forming elements, Re, W and Mo, and decreased the saturation degrees of these elements in γ phase, which can enable the Ru-containing alloy to be more resistant to the formation of TCP phases. It is indicated that the addition of Ru to the Ni-based single crystal superalloy with high content of the refractory alloying element can enhance phase stability.     

Progress of phase-field investigations of γrafting in nickel-base single-crystal superalloys

With the development of nucleation theory,the calculation of phase diagrams(CALPHAD)method and microscopic elasto-plasticity mechanics,it is possible to apply the phase-field method to simulate the γrafting behavior of nickel-base single-crystal superalloys under the conditions of heat treatment,fatigue and creep testing.Based on the experimental progress in γrafting behavior and in combination with the microstructural simulation of the precipitation and rafting of c0phase,this paper reviews the phase-field investigation of γrafting in nickel–base single-crystal superalloys.     

Ti-45%Al合金界面形态及微观结构演化的相场模拟

用相场法对Ti-45%Al合金在近绝对稳定高速定向凝固条件下的液固相变界面形态和微观结构演化进行模拟.结果表明：初始平界面失稳后形成许多细胞晶,在生长速度进一步增大至近绝对稳定平界面过程中,存在细胞晶向高速平界面的转变;体系溶质分布模拟的研究结果表明,由于固液界面处发生溶质截流,体系出现低微观偏析的凝固结构.模拟结果与快速凝固理论相吻合.     

Microstructural evolution and castability prediction in newly designed modern third-generation nickel-based superalloys

The present research aims to establish a quantitative relation between microstructure and chemical composition (i.e., Ti, Al, and Nb) of newly designed nickel-based superalloys. This research attempts to identify an optimum microstructure at which the minimum quantities of γ/γ' and γ/γ″ compounds are achieved and the best castability is predicted. The results demonstrate that the highest quantity of intermetallic eutectics (i.e., 41.5wt%) is formed at 9.8wt% (Ti + Al). A significant quantity of intermetallics formed in superalloy 1 (with a composition of γ-9.8wt% (Ti + Al)), which can deteriorate its castability. The type and morphology of the eutectics changed and the amount considerably decreased with decreasing Ti + Al content in superalloy 2 (with a composition of γ-7.6wt% (Ti + Al), 1.5wt% Nb). Thus, it is predicted that the castability would improve for superalloy 2. The same trend was observed for superalloy 4 (with a composition of γ-3.7wt% (Ti + Al), 4.4wt% Nb). This means that the amount of Laves increases with increasing Nb (to 4.4wt%) and decreasing Ti + Al (to 3.7wt%) in superalloy 4. The best castability was predicted for superalloy 3 (with a composition of γ-5.7wt% (Ti + Al), 2.8wt% Nb).     

相场法模拟定向凝固微观组织演化研究进展

定向凝固是一种新型的铸造成型技术,能够很好地呈现出凝固过程中界面形态的演化过程,而相场法在如今微观组织数值模拟领域中是最具有优势的一种研究方法.介绍了相场法数值模拟的基本原理,阐述了国内外学者对二元或多元合金在受流场、溶质间相互作用和各向异性、过冷等因素条件影响下自由枝晶和小晶面枝晶的相场法模拟的研究进展,说明了采用相场法耦合溶质场和计算相图等方法在其他微观组织中的应用,并且指出了相场法在模拟定向凝固微观组织领域中所存在的不足之处以及未来的发展趋势.     

Effects of Mo addition on microstructure of a 4th generation Ni-based single crystal superalloy

The effects of Mo addition on the microstructure of a 4th generation Ni-based single crystal superalloy were investigated. Mo addition significantly promoted elements Mo, W and Re partition into γ phase and enhanced absolute lattice misfit at 1100 ?°C. The increase of Mo concentration from 2 ?wt% to 4 ?wt% also decreased the content of eutectic islands and the segregation ratios of other alloying elements in the as-cast state, especially Re and W. After heat treatments, the size of γ′ phase and width of γ channels decreased slightly with higher Mo content. More Mo additions slightly enhanced the segregation behavior of Re while reducing the segregation behavior of Mo. However, it revealed that the primary and secondary dendrite arm spacings were barely affected by Mo addition.     

Influence of withdrawal rate on the porosity in a third-generation Ni-based single crystal superalloy

The influence of withdrawal rate on the porosity in a third-generation Ni-based single crystal superalloy was investigated by a quantitative evaluation method. The results showed that the withdrawal rate obviously effected on the average area fraction, number and diameter of porosities except their radius ratios. In consideration of the microstructure observation for dendrite arms, an optimized withdrawal rate was obtained with a minimum porosity level as about 125 μm s~(-1). Simultaneously, a threshold value for the acceptance level of porosities might be set as about 0.1% in order to fulfill the requirements for Ni-based single crystal casting in laboratory scale. Finally, the formation reason of porosity was discussed and it was concluded that the feeding for the volume shrinkage of the last solidified eutectic liquids from the residual liquids and the isolating effect of the morphologies of dendrite arms might be two key factors in controlling the porosities level in Ni-based single crystal superalloy.     

Phase-field method and Materials Genome Initiative （MGI）

Predicting and controlling the microstructure evolution within a material are considered as the‘‘holy grail’’of materials science and engineering.Many important engineering materials are designed by controlling their phase transformations and microstructure evolution.Examples include the improvement of mechanical properties through solid-state precipitation reactions in Nibased superalloys and age-hardened Al alloys,the useful dielectric properties and electro-mechanical coupling effects by manipulating the phase transitions in ferroelectric crystals,and the memory effect of shape-memory alloys by utilizing martensitic transformations.Phase-field method has become the method of choice for modeling three-dimensional microstructure evolution for a wide variety of materials processes.This short article briefly discusses the potential roles that phase-field method can play in the Materials Genome Initiative.     

Microstructure and heat treatment for Ni3Al-based single crystal alloy with different crystal orientations

Ni₃Al-based single crystal alloy IC6SX with different crystal orientations were prepared by seed crystal method. The microstructure and heat treatment of the alloy were investigated. The results showed that the microstructure of the alloy was in dendrite structure, and the crystal orientation had significant effect on the dendrite morphology of this alloy. The precipitated phases of (MoNi)₆C and NiMo appeared in the microstructure of the three alloys with different crystal orientations during solidification process. Compared with other two alloys, the volume fractions of precipitated phases of both (MoNi)₆C and NiMo was the most in the alloy with [111] orientation and the least in the alloy with [001] orientation. The solidus and liquidus temperatures of the alloy IC6SX tested by differential scanning calorimetry (DSC) were 1356 °C and 1387 °C, respectively. Meanwhile, the effect of different solution temperatures on the microstructure of the alloy with different orientations was studied. The results showed that the precipitated phases of (MoNi)₆C and NiMo were eliminated with the solid solution treatment under the condition of 1300 °C/10 h. However, the incipient melting of the alloys occurred due to the dissolution of low melting point phases. As the temperature dropped to 1280 °C, the area of incipient melting in the alloy with different orientations decreased gradually. However, there was no incipient melting appearing in the three alloys with different orientations when the solution treatment temperature dropped to 1260 °C.     

师昌绪在高温合金领域的重大贡献

 师昌绪是当代著名的金属学及材料学科学家。在高温合金领域,最先提出并攻克了包套挤压工艺难关,为变形高温合金的生产开辟了一条新的途径;铸造高温合金方面,研究出中国第一代空心气冷铸造镍基高温合金涡轮叶片,使中国成为世界上第二个采用这种叶片的国家;发现了凝固偏析的新规律,总结了"低偏析合金技术",推动了高温合金的发展,被美国同行尊称为"中国高温合金之父"。     

相场法在凝固数值模拟中的应用

研究了相场方法在纯物质凝固生长过程中计算模拟的应用．通过选取不同过冷度和各向异性系数进行纯物质镍的技晶生长模拟,最后采用加入非平衡扰动的方式,进行了侧向分技生长的模拟．模拟结果表明,模拟中过冷度和各向异性强度需要耦合考虑;非平衡扰动在模拟中不影响尖端生长速度．     

Formation mechanism of interfacial microstructures and mechanical properties of Ti2AlNb/Ni-based superalloy joints brazed with NiCrFeSiB filler metal

Dissimilar brazing of Ti₂AlNb-based alloy and Ni-based wrought superalloy (GH536) was studied using NiCrFeSiB filler metal. The Ti₂AlNb/GH536 joints were analyzed by scanning electron microscope (SEM) equipped with an electron probe micro-analyzer (EPMA), X-ray diffraction (XRD) and transmission electron microscopy (TEM). The formation mechanism of interfacial microstructure and mechanical properties of Ti₂AlNb/GH536 joints were studied. The results indicated that Ti₂Ni(Al,Nb), AlNi₂Ti and TiB₂ reaction layers were formed in the joint adjacent to Ti₂AlNb base metal. These layers resulted in high micro-hardness and the weak link of the joint. γ solid solution was formed through isothermal solidification and β₁-Ni₃Si phase precipitated in the γ solid solution during cooling process. Ni₃B, β₁-Ni₃Si and CrB phases appeared in the centre of the joint. Blocky and needle-like borides formed within the diffusion affected zone of GH536 base alloy. The maximum tensile strength of Ti₂AlNb/GH536 joints reached 425 ?MPa ?at room temperature and the strength value of 373 ?MPa was maintained at 923 ?K.     

硼对第二代镍基单晶高温合金显微组织的影响

硼(B)是强化镍基单晶合金小角度晶界的重要微量元素,但目前关于B对镍基单晶合金显微组织影响的系统报道非常有限。通过对3种不同B含量(质量分数分别为0、0.01%、0.02%)的第二代镍基单晶合金DD11铸态及热处理态组织定量表征,研究了B对相转变温度、(γ+γ′)共晶组织、硼化物的影响。结果表明:B显著降低合金的固液相线,提高铸态共晶组织体积分数;0.01%B的加入,合金中未出现M3B2型硼化物相;而0.02%B的加入,显著促进了骨架状硼化物的形成,降低合金初熔点,引起残余共晶含量的大幅度提高;骨架状硼化物吸收较多的Cr、Mo和W等元素,降低合金的固溶强化效果,可导致单晶合金基体的蠕变性能大幅度降低。研究结果对认识单晶合金中微量元素B的作用机理及优化B成分范围具有理论指导意义。     

Hot-corrosion behavior associated with the evolution of corrosion scales of a Ni-based superalloy in molten salts

The degradation of Ni-based superalloys in molten salts is closely related with the evolution of corrosion scales. In this work, the evolution of corrosion scales, the characteristics of the scale/alloy matrix interface associated with the corrosion mechanisms and the corrosion kinetics of a Ni-based superalloy Ni–20Cr–18W in molten salts were investigated. The outer surface of the corrosion scales was composed of numerous flakes. From the cross-sectional view, the scales gradually presented a layered structure and its formation can be ascribed to the morphology evolution of the inclusions inserted within the scales. It was found that the corrosion progress was a cooperative process involving in both oxidation and sulfuration, and the element of sulfur (S) took the precedence to penetrate into the matrix and resulted in an obvious sulfuration zone nearby the scales/alloy matrix interface. The corrosion activation energy of the investigated alloy was calculated to be 125.27 ?kJ/mol. This work is expected to work out the structural evolution of the corrosion scales and the characteristics of the scale/matrix interface associated with the corrosion mechanisms for Ni-based superalloys.