Hydrogen induced fracture characteristics of single crystal nickel-based superalloys

NASA Technical Reports Server (NTRS)

Chen, Po-Shou; Wilcox, Roy C.

1990-01-01

A stereoscopic method for use with x ray energy dispersive spectroscopy of rough surfaces was adapted and applied to the fracture surfaces single crystals of PWA 1480E to permit rapid orientation determinations of small cleavage planes. The method uses a mathematical treatment of stereo pair photomicrographs to measure the angle between the electron beam and the surface normal. One reference crystal orientation corresponding to the electron beam direction (crystal growth direction) is required to perform this trace analysis. The microstructure of PWA 1480E was characterized before fracture analysis was performed. The fracture behavior of single crystals of the PWA 1480E nickel-based superalloy was studied. The hydrogen-induced fracture behavior of single crystals of the PWA 1480E nickel-based superalloy was also studied. In order to understand the temperature dependence of hydrogen-induced embrittlement, notched single crystals with three different crystal growth orientations near zone axes (100), (110), and (111) were tensile tested at 871 C (1600 F) in both helium and hydrogen atmospheres at 34 MPa. Results and conclusions are given.

Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification

NASA Astrophysics Data System (ADS)

Babu, S. S.; Raghavan, N.; Raplee, J.; Foster, S. J.; Frederick, C.; Haines, M.; Dinwiddie, R.; Kirka, M. K.; Plotkowski, A.; Lee, Y.; Dehoff, R. R.

2018-06-01

Innovative designs for turbines can be achieved by advances in nickel-based superalloys and manufacturing methods, including the adoption of additive manufacturing. In this regard, selective electron beam melting (SEBM) and selective laser melting (SLM) of nickel-based superalloys do provide distinct advantages. Furthermore, the direct energy deposition (DED) processes can be used for repair and reclamation of nickel alloy components. The current paper explores opportunities for innovation and qualification challenges with respect to deployment of AM as a disruptive manufacturing technology. In the first part of the paper, fundamental correlations of processing parameters to defect tendency and microstructure evolution will be explored using DED process. In the second part of the paper, opportunities for innovation in terms of site-specific control of microstructure during processing will be discussed. In the third part of the paper, challenges in qualification of AM parts for service will be discussed and potential methods to alleviate these issues through in situ process monitoring, and big data analytics are proposed.

Addition of silicon improves oxidation resistance of nickel based superalloys

NASA Technical Reports Server (NTRS)

Lowell, C. E.; Miner, R. V., Jr.

1974-01-01

Specific weight changes of nickel-base superalloy B-1900 and B-1900 + 1% Si specimens were tested at 1273 K. B-1900 was losing weight at an increasing rate due to spalling of oxide scale while B-1900 + 1% Si was still gaining weight at low, nearly constant rate. Similar comparison in weight change was observed for specimens tested at 1373 K.

Strainrange partitioning behavior of the nickel-base superalloys, Rene' 80 and in 100

NASA Technical Reports Server (NTRS)

Halford, G. R.; Nachtigall, A. J.

1978-01-01

A study was made to assess the ability of the method of Strainrange Partitioning (SRP) to both correlate and predict high-temperature, low cycle fatigue lives of nickel base superalloys for gas turbine applications. The partitioned strainrange versus life relationships for uncoated Rene' 80 and cast IN 100 were also determined from the ductility normalized-Strainrange Partitioning equations. These were used to predict the cyclic lives of the baseline tests. The life predictability of the method was verified for cast IN 100 by applying the baseline results to the cyclic life prediction of a series of complex strain cycling tests with multiple hold periods at constant strain. It was concluded that the method of SRP can correlate and predict the cyclic lives of laboratory specimens of the nickel base superalloys evaluated in this program.

Cyclic Oxidation and Hot Corrosion Behavior of Nickel-Iron-Based Superalloy

NASA Astrophysics Data System (ADS)

Chellaganesh, D.; Adam Khan, M.; Winowlin Jappes, J. T.; Sathiyanarayanan, S.

2018-01-01

The high temperature oxidation and hot corrosion behavior of nickel-iron-based superalloy are studied at 900 ° and 1000 °C. The significant role of alloying elements with respect to the exposed medium is studied in detail. The mass change per unit area was catastrophic for the samples exposed at 1000 °C and gradual increase in mass change was observed at 900 °C for both the environments. The exposed samples were further investigated with SEM, EDS and XRD analysis to study the metallurgical characteristics. The surface morphology has expressed the in situ nature of the alloy and its affinity toward the environment. The EDS and XRD analysis has evidently proved the presence of protective oxides formation on prolonged exposure at elevated temperature. The predominant oxide formed during the exposure at high temperature has a major contribution toward the protection of the samples. The nickel-iron-based superalloy is less prone to oxidation and hot corrosion when compared to the existing alloy in gas turbine engine simulating marine environment.

Recovery of Nickel from Nickel-Based Superalloy Scraps by Utilizing Molten Zinc

NASA Astrophysics Data System (ADS)

Yagi, Ryohei; Okabe, Toru H.

2017-02-01

With the purpose of developing a new process for recycling nickel (Ni) directly from superalloy scraps, a fundamental study on the extraction and separation of Ni was carried out using molten zinc (Zn) as the extraction medium. In order to examine the reaction between molten Zn and the Ni-based superalloy, superalloy samples and Zn shots were heated at 1173 K (900 °C) for 6 hours. After heating, the superalloy samples fully reacted with Zn and dissolved in molten Zn. The Zn-alloyed sample obtained by slow cooling consisted of two separated upper and lower phases. In the upper part of the sample, only Zn and the Zn-Ni alloys were found; in the lower part, an intermetallic alloy consisting of refractory metals such as rhenium (Re) and tantalum (Ta) was found. This result shows that Ni and refractory metals contained in the scrap can be separated by utilizing the density differences between the Zn-Ni alloy and the refractory metals in molten Zn. Vacuum treatment of the upper part of the Zn-alloyed sample at 1173 K (900 °C) reduced the concentration of Zn in the sample from 97.0 to 0.4 mass pct. After Zn removal, a Ni alloy containing Ni with a purity of 85.3 to 86.1 mass pct and negligible quantities (<0.1 mass pct) of Re and Ta was obtained. Moreover, recovered Zn metal after distillation had a purity of more than 99.9 mass pct. Therefore, this process could be an environmentally sound recycling process that can recover Ni from superalloy scraps without the consumption of Zn or the generation of toxic wastes solutions.

Microstructure-property relationships in directionally solidified single crystal nickel-base superalloys

NASA Technical Reports Server (NTRS)

Mackay, R. A.; Nathal, M. V.

1986-01-01

Some of the microstructural features which influence the creep properties of directionally solidified and single crystal nickel-base superalloys are discussed. Gamma precipitate size and morphology, gamma-gamma lattice mismatch, phase instability, alloy composition, and processing variations are among the factors considered. Recent experimental results are reviewed and related to the operative deformation mechanisms and to the corresponding mechanical properties. Special emphasis is placed on the creep behavior of single crystal superalloys at high temperatures, where directional gamma coarsening is prominent, and at lower temperatures, where gamma coarsening rates are significantly reduced. It can be seen that very subtle changes in microstructural features can have profound effects on the subsequent properties of these materials.

Understanding the roles of the strategic element cobalt in nickel base superalloys

NASA Technical Reports Server (NTRS)

Stephens, J. R.; Dreshfield, R. L.

1983-01-01

The United States imports over 90% of its cobalt, chromium, columbium, and tantalum, all key elements in high temperature nickel base superalloys for aircraft gas turbine disks and airfoils. Research progress in understanding the roles of cobalt and some possible substitutes effects on microstructure, mechanical properties, and environmental resistance of turbine alloys is discussed.

Anisotropic constitutive modeling for nickel base single crystal superalloys using a crystallographic approach

NASA Technical Reports Server (NTRS)

Stouffer, D. C.; Sheh, M. Y.

1988-01-01

A micromechanical model based on crystallographic slip theory was formulated for nickel-base single crystal superalloys. The current equations include both drag stress and back stress state variables to model the local inelastic flow. Specially designed experiments have been conducted to evaluate the effect of back stress in single crystals. The results showed that (1) the back stress is orientation dependent; and (2) the back stress state variable in the inelastic flow equation is necessary for predicting anelastic behavior of the material. The model also demonstrated improved fatigue predictive capability. Model predictions and experimental data are presented for single crystal superalloy Rene N4 at 982 C.

Creep and stress rupture of a mechanically alloyed oxide dispersion and precipitation strengthened nickel-base superalloy

NASA Technical Reports Server (NTRS)

Howson, T. E.; Tien, J. K.; Mervyn, D. A.

1980-01-01

The creep and stress rupture behavior of a mechanically alloyed oxide dispersion strengthened (ODS) and gamma-prime precipitation strengthened nickel-base alloy (alloy MA 6000E) was studied at intermediate and elevated temperatures. At 760 C, MA 6000E exhibits the high creep strength characteristic of nickel-base superalloys and at 1093 C the creep strength is superior to other ODS nickel-base alloys. The stress dependence of the creep rate is very sharp at both test temperatures and the apparent creep activation energy measured around 760 C is high, much larger in magnitude than the self-diffusion energy. Stress rupture in this large grain size material is transgranular and crystallographic cracking is observed. The rupture ductility is dependent on creep strain rate, but usually is low. These and accompanying microstructural results are discussed with respect to other ODS alloys and superalloys and the creep behavior is rationalized by invoking a recently-developed resisting stress model of creep in materials strengthened by second phase particles.

The Tensile Properties of Advanced Nickel-Base Disk Superalloys During Quenching Heat Treatments

NASA Technical Reports Server (NTRS)

Gabb, Timothy P.; Gayda, John; Kantzos, Pete T.; Biles, Tiffany; Konkel, William

2001-01-01

There is a need to increase the temperature capabilities of superalloy turbine disks. This would allow full utilization of higher temperature combustor and airfoil concepts under development. One approach to meet this goal is to modify the processing and chemistry of advanced alloys, while preserving the ability to use rapid cooling supersolvus heat treatments to achieve coarse grain, fine gamma prime microstructures. An important step in this effort is to understand the key high temperature tensile properties of advanced alloys as they exist during supersolvus heat treatments. This could help in projecting cracking tendencies of disks during quenches from supersolvus heat treatments. The objective of this study was to examine the tensile properties of two advanced disk superalloys during simulated quenching heat treatments. Specimens were cooled from the solution heat treatment temperatures at controlled rates, interrupted, and immediately tensile tested at various temperatures. The responses and failure modes were compared and related to the quench cracking tendencies of disk forgings.

Gamma Prime Precipitate Evolution During Aging of a Model Nickel-Based Superalloy

NASA Astrophysics Data System (ADS)

Goodfellow, A. J.; Galindo-Nava, E. I.; Christofidou, K. A.; Jones, N. G.; Martin, T.; Bagot, P. A. J.; Boyer, C. D.; Hardy, M. C.; Stone, H. J.

2018-03-01

The microstructural stability of nickel-based superalloys is critical for maintaining alloy performance during service in gas turbine engines. In this study, the precipitate evolution in a model polycrystalline Ni-based superalloy during aging to 1000 hours has been studied via transmission electron microscopy, atom probe tomography, and neutron diffraction. Variations in phase composition and precipitate morphology, size, and volume fraction were observed during aging, while the constrained lattice misfit remained constant at approximately zero. The experimental composition of the γ matrix phase was consistent with thermodynamic equilibrium predictions, while significant differences were identified between the experimental and predicted results from the γ' phase. These results have implications for the evolution of mechanical properties in service and their prediction using modeling methods.

Anisotropic constitutive modeling for nickel-base single crystal superalloys. Ph.D. Thesis

NASA Technical Reports Server (NTRS)

Sheh, Michael Y.

1988-01-01

An anisotropic constitutive model was developed based on crystallographic slip theory for nickel base single crystal superalloys. The constitutive equations developed utilizes drag stress and back stress state variables to model the local inelastic flow. Specially designed experiments were conducted to evaluate the existence of back stress in single crystal superalloy Rene N4 at 982 C. The results suggest that: (1) the back stress is orientation dependent; and (2) the back stress state variable is required for the current model to predict material anelastic recovery behavior. The model was evaluated for its predictive capability on single crystal material behavior including orientation dependent stress-strain response, tension/compression asymmetry, strain rate sensitivity, anelastic recovery behavior, cyclic hardening and softening, stress relaxation, creep and associated crystal lattice rotation. Limitation and future development needs are discussed.

Feasibility of Electrochemical Deposition of Nickel/Silicon Carbide Fibers Composites over Nickel Superalloys

NASA Astrophysics Data System (ADS)

Ambrosio, E. P.; Abdul Karim, M. R.; Pavese, M.; Biamino, S.; Badini, C.; Fino, P.

2017-05-01

Nickel superalloys are typical materials used for the hot parts of engines in aircraft and space vehicles. They are very important in this field as they offer high-temperature mechanical strength together with a good resistance to oxidation and corrosion. Due to high-temperature buckling phenomena, reinforcement of the nickel superalloy might be needed to increase stiffness. For this reason, it was thought to investigate the possibility of producing composite materials that might improve properties of the metal at high temperature. The composite material was produced by using electrochemical deposition method in which a composite with nickel matrix and long silicon carbide fibers was deposited over the nickel superalloy. The substrate was Inconel 718, and monofilament continuous silicon carbide fibers were chosen as reinforcement. Chemical compatibility was studied between Inconel 718 and the reinforcing fibers, with fibers both in an uncoated condition, and coated with carbon or carbon/titanium diboride. Both theoretical calculations and experiments were conducted, which suggested the use of a carbon coating over the fibers and a buffer layer of nickel to avoid unwanted reactions between the substrate and silicon carbide. Deposition was then performed, and this demonstrated the practical feasibility of the process. Yield strength was measured to detect the onset of interface debonding between the substrate and the composite layer.

Use of Precious Metal-Modifed Nickel-Base Superalloys for Thin Gage Applications (Preprint)

DTIC Science & Technology

2011-04-01

superalloys are being investigated for use in thin gage applications, such as thermal protection systems or heat exchangers, due to their strength and...atomic % total) in place of the platinum and iridium. 15. SUBJECT TERMS thermal protection systems, nickel, superalloy, thermomechanical processing...use in thin gage applications, such as thermal protection systems or heat exchangers, due to their strength and inherent oxidation resistance at

Elevated temperature mechanical properties and residual tensile properties of two cast superalloys and several nickel-base oxide dispersion strengthened alloys

NASA Technical Reports Server (NTRS)

Whittenberger, J. D.

1981-01-01

The elevated temperature tensile, stress-rupture and creep properties and residual tensile properties after creep straining have been determined for two cast superalloys and several wrought Ni-16Cr-4Al-yttria oxide dispersion strengthened (ODS) alloys. The creep behavior of the ODS alloys is similar to that of previously studied ODS nickel alloys. In general, the longitudinal direction is stronger than the long transverse direction, and creep is at least partially due to a diffusional creep mechanism as dispersoid-free zones were observed after creep-rupture testing. The tensile properties of the nickel-base superalloy B-1900 and cobalt-base superalloy MAR-M509 are not degraded by prior elevated temperature creep straining (at least up to 1 pct) between 1144 and 1366 K. On the other hand, the room temperature tensile properties of ODS nickel-base alloys can be reduced by prior creep strains of 0.5 pct or less between 1144 and 1477 K, with the long transverse direction being more susceptible to degradation than the longitudinal direction.

Correlation Between the Microstructural Defects and Residual Stress in a Single Crystal Nickel-Based Superalloy During Different Creep Stages

NASA Astrophysics Data System (ADS)

Mo, Fangjie; Wu, Erdong; Zhang, Changsheng; Wang, Hong; Zhong, Zhengye; Zhang, Jian; Chen, Bo; Hofmann, Michael; Gan, Weimin; Sun, Guangai

2018-03-01

The present work attempts to reveal the correlation between the microstructural defects and residual stress in the single crystal nickel-based superalloy, both of which play the significant role on properties and performance. Neutron diffraction was employed to investigate the microstructural defects and residual stresses in a single crystal (SC) nickel-based superalloy, which was subjected to creeping under 220 MPa and 1000 °C for different times. The measured superlattice and fundamental lattice reflections confirm that the mismatch and tetragonal distortions with c/a > 1 exist in the SC superalloy. At the initially unstrained state, there exists the angular distortion between γ and γ' phases with small triaxial compressive stresses, ensuring the structural stability of the superalloy. After creeping, the tetragonal distortion for the γ phase is larger than that for the γ' phase. With increasing the creeping time, the mismatch between γ and γ' phases increases to the maximum, then decreases gradually and finally remains unchanged. The macroscopic residual stress shows a similar behavior with the mismatch, indicating the correlation between them. Based on the model of shear and dislocations, the evolution of microstructural defects and residual stress are reasonably explained. The effect of shear is dominant at the primary creep stage, which greatly enlarges the mismatch and the residual stress. The dislocations weaken the effect of shear for the further creep stage, resulting in the decrease of the mismatch and relaxation of the residual stress. Those findings add some helpful understanding into the microstructure-performance relationship in the SC nickel-based superalloy, which might provide the insight to materials design and applications.

Additive Manufacturing of Nickel-Base Superalloy IN100 Through Scanning Laser Epitaxy

NASA Astrophysics Data System (ADS)

Basak, Amrita; Das, Suman

2018-01-01

Scanning laser epitaxy (SLE) is a laser powder bed fusion (LPBF)-based additive manufacturing process that uses a high-power laser to consolidate metal powders facilitating the fabrication of three-dimensional objects. In the present study, SLE is used to produce samples of IN100, a high-γ' non-weldable nickel-base superalloy on similar chemistry substrates. A thorough analysis is performed using various advanced material characterization techniques such as high-resolution optical microscopy, scanning electron microscopy, energy dispersive x-ray spectroscopy, and Vickers microhardness measurements to characterize and compare the quality of the SLE-fabricated IN100 deposits with the investment cast IN100 substrates. The results show that the IN100 deposits have a finer γ/γ' microstructure, weaker elemental segregation, and higher microhardness compared with the substrate. Through this study, it is demonstrated that the SLE process has tremendous potential in the repair and manufacture of gas turbine hot-section components.

The effect of alloying on gamma and gamma prime in nickel-base superalloys

NASA Technical Reports Server (NTRS)

Dreshfield, R. L.; Wallace, J. F.

1972-01-01

An investigation was conducted to determine the compositional limits of gamma and gamma prime phases in nickel-base superalloys. Fifty-one nickel-base alloys were melted under vacuum and heat treated for 4 hours at 1190 C followed by 1008 hours at 850 C. The alloys had the following composition ranges: A1 4.0 to 13 atomic percent, Cr 6.5 to 20.5 percent, Ti 0.25 to 4.75 percent, Mo 0.0 to 6.0 percent, and W 0.0 to 4.0 percent. The residues from the ammonium sulfate electrolytic extraction for the two-phase alloys were analyzed chemically and by X-ray diffraction. The results of the investigation were used to assemble a mathematical model of the gamma-gamma prime region of the Ni-Al-Cr-Ti-Mo-W system. A computer program was written to analyze the model of the phase diagram. Some of these results are also presented graphically. The resulting model is capable of satisfactorily predicting the compositions of conjugate gamma-gamma prime phases in the alloys investigated and twelve of fifteen commercial superalloys studied.

Anisotropy of high temperature strength in precipitation-hardened nickel-base superalloy single crystals

NASA Technical Reports Server (NTRS)

Nakagawa, Y. G.; Terashima, H.; Yoshizawa, H.; Ohta, Y.; Murakami, K.

1986-01-01

The anisotropy of high temperature strength of nickel-base superalloy, Alloy 454, in service for advanced jet engine turbine blades and vanes, was investigated. Crystallographic orientation dependence of tensile yield strength, creep and creep rupture strength was found to be marked at about 760C. In comparison with other single crystal data, a larger allowance in high strength off-axial orientation from the 001 axis, and relatively poor strength at near the -111 axis were noted. From transmission electron microscopy the anisotropic characteristics of this alloy were explained in terms of available slip systems and stacking geometries of gamma-prime precipitate cuboids which are well hardened by a large tantalum content. 100 cube slip was considered to be primarily responsible for the poor strength of the -111 axis orientation replacing the conventional 111 plane slip systems.

The use of precious-metal-modified nickel-based superalloys for thin gage applications

NASA Astrophysics Data System (ADS)

Ballard, Donna L.; Pilchak, Adam L.

2010-10-01

Precious-metal-modified nickel-based superalloys are being investigated for use in thin gage applications, such as thermal protection systems or heat exchangers, due to their strength and inherent oxidation resistance at temperatures in excess of 1,050°C. This overview paper summarizes the Air Force Research Laboratory (AFRL) interest in experimental two-phase γ-Ni + γ'-Ni3Al superalloys. The AFRL is interested in alloys with a based composition of Ni-15Al-5Cr (at. %) with carbon, boron, and zirconium additions for grain-boundary refinement and strengthening. The alloys currently being evaluated also contain 4-5 at.% of platinum-group metals, in this case platinum and iridium. The feasibility of hot rolling these alloys to a final thickness of 0.12-0.25 mm and obtaining a nearly fully recrystallized microstructure was demonstrated.

Method of improving fatigue life of cast nickel based superalloys and composition

DOEpatents

Denzine, Allen F.; Kolakowski, Thomas A.; Wallace, John F.

1978-03-14

The invention consists of a method of producing a fine equiaxed grain structure (ASTM 2-4) in cast nickel-base superalloys which increases low cycle fatigue lives without detrimental effects on stress rupture properties to temperatures as high as 1800.degree. F. These superalloys are variations of the basic nickel-chromium matrix, hardened by gamma prime [Ni.sub.3 (Al, Ti)] but with optional additions of cobalt, tungsten, molybdenum, vanadium, columbium, tantalum, boron, zirconium, carbon and hafnium. The invention grain refines these alloys to ASTM 2 to 4 increasing low cycle fatigue life by a factor of 2 to 5 (i.e. life of 700 hours would be increased to 1400 to 3500 hours for a given stress) as a result of the addition of 0.01% to 0.2% of a member of the group consisting of boron, zirconium and mixtures thereof to aid heterogeneous nucleation. The alloy is vacuum melted and heated to 250.degree.-400.degree. F. above the melting temperature, cooled to partial solidification, thus resulting in said heterogeneous nucleation and fine grains, then reheated and cast at about 50.degree.-100.degree. F. of superheat. Additions of 0.1% boron and 0.1% zirconium (optional) are the preferred nucleating agents.

Nickel base alloy. [for gas turbine engine stator vanes

NASA Technical Reports Server (NTRS)

Freche, J. C.; Waters, W. J. (Inventor)

1977-01-01

A nickel base superalloy for use at temperatures of 2000 F (1095 C) to 2200 F (1205 C) was developed for use as stator vane material in advanced gas turbine engines. The alloy has a nominal composition in weight percent of 16 tungsten, 7 aluminum, 1 molybdenum, 2 columbium, 0.3 zirconium, 0.2 carbon and the balance nickel.

Solution and Aging of MAR-M246 Nickel-Based Superalloy

NASA Astrophysics Data System (ADS)

Baldan, Renato; da Silva, Antonio Augusto Araújo Pinto; Nunes, Carlos Angelo; Couto, Antonio Augusto; Gabriel, Sinara Borborema; Alkmin, Luciano Braga

2017-02-01

Solution and aging heat-treatments play a key role for the application of the superalloys. The aim of this work is to evaluate the microstructure of the MAR-M246 nickel-based superalloy solutioned at 1200 and 1250 °C for 330 min and aged at 780, 880 and 980 °C for 5, 20 and 80 h. The γ' solvus, solidus and liquidus temperatures were calculated with the aid of the JMatPro software (Ni database). The as-cast and heat-treated samples were characterized by SEM/EDS and SEM-FEG. The γ' size precipitated in the aged samples was measured and compared with JMatPro simulations. The results have shown that the sample solutioned at 1250 °C for 330 min showed a very homogeneous γ matrix with carbides and cubic γ' precipitates uniformly distributed. The mean γ' size of aged samples at 780 and 880 °C for 5, 20 and 80 h did not present significant differences when compared to the solutioned sample. However, a significant increasing in the γ' particles was observed at 980 °C, evidenced by the large mean size of these particles after 80 h of aging heat-treatment.

Evolution of Microstructure in a Nickel-based Superalloy as a Function of Ageing Time

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chen, Wei-Ren; Smith, Gregory Scott; Porcar, L.

2011-01-01

An experimental investigation, combining synchrotron X-ray powder diffraction, small-angle neutron-scattering, and transmission electron microscopy, has been undertaken to study the microstructure of nanoprecipitates in a nickel-based superalloy. Upon increasing the ageing time during a heat-treatment process, the average size of the precipitates first decreases before changing to a monotonical growth stage. Possible reasons for this observed structural evolution, which is predicted thermodynamically, are suggested.

The cyclic stress-strain behavior of a nickel-base superalloy at 650 C

NASA Technical Reports Server (NTRS)

Gabb, T. P.; Welsch, G. E.

1986-01-01

It is pointed out that examinations of the monotonic tensile and fatigue behaviors of single crystal nickel-base superalloys have disclosed orientation-dependent tension-compression anisotropies and significant differences in the mechanical response of octahedral and cube slip at intermediate temperatures. An examination is conducted of the cyclic hardening response of the single crystal superalloy PWA 1480 at 650 C. In the considered case, tension-compression anisotropy is present, taking into account primarily conditions under which a single slip system is operative. Aspects of a deformation by single slip are considered along with cyclic hardening anisotropy in tension and compression. It is found that specimens deforming by octahedral slip on a single slip system have similar hardening responses in tensile and low cycle fatigue loading. Cyclic strain hardening is very low for specimens displaying single slip.

Fiber laser welding of nickel based superalloy Inconel 625

NASA Astrophysics Data System (ADS)

Janicki, Damian M.

2013-01-01

The paper describes the application of single mode high power fiber laser (HPFL) for the welding of nickel based superalloy Inconel 625. Butt joints of Inconel 625 sheets 0,8 mm thick were laser welded without an additional material. The influence of laser welding parameters on weld quality and mechanical properties of test joints was studied. The quality and mechanical properties of the joints were determined by means of tensile and bending tests, and micro hardness tests, and also metallographic examinations. The results showed that a proper selection of laser welding parameters provides non-porous, fully-penetrated welds with the aspect ratio up to 2.0. The minimum heat input required to achieve full penetration butt welded joints with no defect was found to be 6 J/mm. The yield strength and ultimate tensile strength of the joints are essentially equivalent to that for the base material.

Replacing critical and strategic refractory metal elements in nickel-base superalloys. [NASA's COSAM program

NASA Technical Reports Server (NTRS)

Stephens, J. R.; Dreshfield, R. L.; Nathal, M. V.

1983-01-01

Because of the import status and essential nature of their use, cobalt, chromium, tantalum, and niobium were identified as strategic and critical in the aerospace industry. NASA's Conservation of Strategic Aerospace Materials (COSAM) program aims to reduce the need for strategic materials used in gas turbine engines. Technological thrusts in two major areas are under way to meet the primary objective of conserving the use of strategic materials in nickelbase superalloys. These thrusts consist of strategic element substitution and alternative material identification. The program emphasizes cooperative research teams involving NASA Lewis Research Center, universities, and industry. The adoption of refractory metals in nickel-base superalloys is summarized including their roles in mechanical strengthening and environmental resistance; current research activities under way in the COSAM Program are presented as well as research findings to date.

Computational Thermodynamic Study to Predict Complex Phase Equilibria in the Nickel-Base Superalloy Rene N6

NASA Technical Reports Server (NTRS)

Copland, Evan H.; Jacobson, Nathan S.; Ritzert, Frank J.

2001-01-01

A previous study by Ritzert et al. on the formation and prediction of topologically closed packed (TCP) phases in the nickel-base superalloy Rene' N6 is re-examined with computational thermodynamics. The experimental data on phase distribution in forty-four alloys with a composition within the patent limits of the nickel-base superalloy Rene' N6 provide a good basis for comparison to and validation of a commercial nickel superalloy database used with ThermoCalc. Volume fraction of the phases and partitioning of the elements are determined for the forty-four alloys in this dataset. The baseline heat treatment of 400 h at 1366 K was used. This composition set is particularly interesting since small composition differences lead to dramatic changes in phase composition. In general the calculated values follow the experimental trends. However, the calculations indicated no TCP phase formation when the experimental measurements gave a volume percent of TCP phase less than 2 percent. When TCP phases were predicted, the calculations under-predict the volume percent of TCP phases by a factor of 2 to 8. The calculated compositions of the gamma and gamma' phases show fair agreement with the measurements. However, the calculated compositions of the P Phase do not agree with those measured. This may be due to inaccuracies in the model parameters for P phase and/or issues with the microprobe analyses of these phases. In addition, phase fraction diagrams and sigma and P phase solvus temperatures are calculated for each of the alloys. These calculations indicate that P phase is the primary TCP phase formed for the alloys considered here at 1366 K. Finally, a series of isopleths are calculated for each of the seven alloying elements. These show the effect of each alloying element on creating TCP phases.

Effect of Heat Treatment Process on Microstructure and Fatigue Behavior of a Nickel-Base Superalloy

PubMed Central

Zhang, Peng; Zhu, Qiang; Chen, Gang; Qin, Heyong; Wang, Chuanjie

2015-01-01

The study of fatigue behaviors for nickel-base superalloys is very significant because fatigue damage results in serious consequences. In this paper, two kinds of heat treatment procedures (Pro.I and Pro.II) were taken to investigate the effect of heat treatment on microstructures and fatigue behaviors of a nickel-base superalloy. Fatigue behaviors were studied through total strain controlled mode at 650 °C. Manson-Coffin relationship and three-parameter power function were used to predict fatigue life. A good link between the cyclic/fatigue behavior and microscopic studies was established. The cyclic deformation mechanism and fatigue mechanism were discussed. The results show that the fatigue resistance significantly drops with the increase of total strain amplitudes. Manson-Coffin relationship can well predict the fatigue life for total strain amplitude from 0.5% to 0.8%. The fatigue resistance is related with heat treatment procedures. The fatigue resistance performance of Pro.I is better than that of Pro.II. The cyclic stress response behaviors are closely related to the changes of the strain amplitudes. The peak stress of the alloy gradually increases with the increase of total strain amplitudes. The main fracture mechanism is inhomogeneous deformation and the different interactions between dislocations and γ′ precipitates. PMID:28793559

Effect of Crystal Orientation on Fatigue Failure of Single Crystal Nickel Base Turbine Blade Superalloys

NASA Technical Reports Server (NTRS)

Arakere, N. K.; Swanson, G.

2002-01-01

High cycle fatigue (HCF) induced failures in aircraft gas turbine and rocket engine turbopump blades is a pervasive problem. Single crystal nickel turbine blades are being utilized in rocket engine turbopumps and jet engines throughout industry because of their superior creep, stress rupture, melt resistance, and thermomechanical fatigue capabilities over polycrystalline alloys. Currently the most widely used single crystal turbine blade superalloys are PWA 1480/1493, PWA 1484, RENE' N-5 and CMSX-4. These alloys play an important role in commercial, military and space propulsion systems. Single crystal materials have highly orthotropic properties making the position of the crystal lattice relative to the part geometry a significant factor in the overall analysis. The failure modes of single crystal turbine blades are complicated to predict due to the material orthotropy and variations in crystal orientations. Fatigue life estimation of single crystal turbine blades represents an important aspect of durability assessment. It is therefore of practical interest to develop effective fatigue failure criteria for single crystal nickel alloys and to investigate the effects of variation of primary and secondary crystal orientation on fatigue life. A fatigue failure criterion based on the maximum shear stress amplitude /Delta(sub tau)(sub max))] on the 24 octahedral and 6 cube slip systems, is presented for single crystal nickel superalloys (FCC crystal). This criterion reduces the scatter in uniaxial LCF test data considerably for PWA 1493 at 1200 F in air. Additionally, single crystal turbine blades used in the alternate advanced high-pressure fuel turbopump (AHPFTP/AT) are modeled using a large-scale three-dimensional finite element model. This finite element model is capable of accounting for material orthotrophy and variation in primary and secondary crystal orientation. Effects of variation in crystal orientation on blade stress response are studied based on 297

High-Temperature Oxidation Behavior of Two Nickel-Based Superalloys Produced by Metal Injection Molding for Aero Engine Applications

NASA Astrophysics Data System (ADS)

Albert, Benedikt; Völkl, Rainer; Glatzel, Uwe

2014-09-01

For different high-temperature applications like aero engines or turbochargers, metal injection molding (MIM) of superalloys is an interesting processing alternative. For operation at high temperatures, oxidation behavior of superalloys produced by MIM needs to match the standard of cast or forged material. The oxidation behavior of nickel-based superalloys Inconel 713 and MAR-M247 in the temperature interval from 1073 K to 1373 K (800 °C to 1100 °C) is investigated and compared to cast material. Weight gain is measured discontinuously at different oxidation temperatures and times. Analysis of oxidized samples is done via SEM and EDX-measurements. MIM samples exhibit homogeneous oxide layers with a thickness up to 4 µm. After processing by MIM, Inconel 713 exhibits lower weight gain and thinner oxide layers than MAR-M247.

Development and research of a rhenium-free high-temperature nickel superalloy for the turbine rotor blades in aviation GTE

NASA Astrophysics Data System (ADS)

Shmotin, Yu. N.; Logunov, A. V.; Leshchenko, I. A.; Danilov, D. V.

2016-12-01

The studies directed on designing an advanced rhenium-free nickel superalloy, which is an analog of ZhS32VI alloy, are performed. The chemical composition of the alloy has been found and an experimental alloy batch has been melted (10 kg). Microstructural and metallographic studies and strength tests are carried out. The new single-crystal superalloy has a long-term strength σ1000 100= 238-248 MPa at a density of 8.87 g/cm3.

The Microstructure of RR1000 Nickel-Base Superalloy: The FIB-SEM Dual-Beam Approach

NASA Astrophysics Data System (ADS)

Croxall, S. A.; Hardy, M. C.; Stone, H. J.; Midgley, P. A.

Nickel-base superalloys are aerospace materials that exhibit exceptional mechanical properties and corrosion resistance at very high temperatures. RR1000 is used in discs in gas turbine engines, where temperatures reach in excess of 650°C with high mechanical stresses. Study of the microstructure at the micron and sub-micron level has conventionally been undertaken using scanning electron microscope images, often meaning the underlying 3D microstructure can be inferred only with additional knowledge. Using a dual-beam workstation, we are able to interrogate directly the 3D microstructure using a serial sectioning approach. The 3D data set, typically (10µm)3 in volume, reveals microstructural detail with lateral resolution of circa 8nm and a depth resolution dictated by the slice thickness, typically 50nm. Morphological and volumetric analysis of the 3D reconstruction of RR1000 superalloy reveals microstructural details hitherto unseen.

Evidence of multimicrometric coherent γ' precipitates in a hot-forged γ-γ' nickel-based superalloy.

PubMed

Charpagne, M-A; Vennéguès, P; Billot, T; Franchet, J-M; Bozzolo, N

2016-07-01

This paper demonstrates the existence of large γ' precipitates (several micrometres in diameter) that are coherent with their surrounding matrix grain in a commercial γ-γ' nickel-based superalloy. The use of combined energy dispersive X-ray spectrometry and electron backscattered diffraction (EBSD) analyses allowed for revealing that surprising feature, which was then confirmed by transmission electron microscopy (TEM). Coherency for such large second-phase particles is supported by a very low crystal lattice misfit between the two phases, which was confirmed thanks to X-ray diffractograms and TEM selected area electron diffraction patterns. Dynamic recrystallization of polycrystalline γ-γ' nickel-based superalloys has been extensively studied in terms of mechanisms and kinetics. As in many materials with low stacking fault energy, under forging conditions, the main softening mechanism is discontinuous dynamic recrystallization. This mechanism occurs with preferential nucleation on the grain boundaries of the deformed matrix. The latter is then being consumed by the growth of the newly formed grains of low energy and by nucleation that keeps generating new grains. In the case of sub-solvus forging, large γ' particles usually pin the migrating boundaries and thus limit grain growth to a size which is determined by the distribution of second-phase particles, in good agreement with the Smith-Zener model. Under particular circumstances, the driving force associated with the difference in stored energy between the growing grains and the matrix can be large enough that the pinning forces can be overcome, and some grains can then reach much larger grain sizes. In the latter exceptional case, some intragranular primary γ' particles can be observed, although they are almost exclusively located on grain boundaries and triple junctions otherwise. In both cases, primary precipitates have no special orientation relationship with the surrounding matrix grain(s). This

Effect of Crystal Orientation on Fatigue Failure of Single Crystal Nickel Base Turbine Blade Superalloys

NASA Technical Reports Server (NTRS)

Arakere, Nagaraj K.; Swanson, Gregory R.

2000-01-01

High Cycle Fatigue (HCF) induced failures in aircraft gas-turbine engines is a pervasive problem affecting a wide range of components and materials. HCF is currently the primary cause of component failures in gas turbine aircraft engines. Turbine blades in high performance aircraft and rocket engines are increasingly being made of single crystal nickel superalloys. Single-crystal Nickel-base superalloys were developed to provide superior creep, stress rupture, melt resistance and thermomechanical fatigue capabilities over polycrystalline alloys previously used in the production of turbine blades and vanes. Currently the most widely used single crystal turbine blade superalloys are PWA 1480/1493 and PWA 1484. These alloys play an important role in commercial, military and space propulsion systems. PWA1493, identical to PWA1480, but with tighter chemical constituent control, is used in the NASA SSME (Space Shuttle Main Engine) alternate turbopump, a liquid hydrogen fueled rocket engine. Objectives for this paper are motivated by the need for developing failure criteria and fatigue life evaluation procedures for high temperature single crystal components, using available fatigue data and finite element modeling of turbine blades. Using the FE (finite element) stress analysis results and the fatigue life relations developed, the effect of variation of primary and secondary crystal orientations on life is determined, at critical blade locations. The most advantageous crystal orientation for a given blade design is determined. Results presented demonstrates that control of secondary and primary crystallographic orientation has the potential to optimize blade design by increasing its resistance to fatigue crack growth without adding additional weight or cost.

The Potential Link Between High Angle Grain Boundary Morphology and Grain Boundary Deformation in a Nickel-Based Superalloy (Postprint)

DTIC Science & Technology

2015-06-01

Ghosh, M.K. Samal , Multiscale Crystal Plasticity Modeling of Microtwinning Induced Deformation in Gamma–Gamma Prime Nickel Based Superalloys, Shanghai...University, Shanghai, Peoples Republic of China, 2011, pp. 487–488. [3] H. Deuchman, P.J. Phillips, N. Zhou, M. Samal , S. Ghosh, Y. Wang, M.J. Mills

Evolution of Micro-Pores in a Single-Crystal Nickel-Based Superalloy During Solution Heat Treatment

NASA Astrophysics Data System (ADS)

Li, Xiangwei; Wang, Li; Dong, Jiasheng; Lou, Langhong; Zhang, Jian

2017-06-01

Evolution of micro-pores in a third-generation single-crystal nickel-based superalloy during solution heat treatment at 1603 K (1330 °C) was investigated by X-ray computed tomography. 3D information including morphology, size, number, and volume fraction of micro-pores formed during solidification (S-pores) and solution (H-pores) was analyzed. The growth behaviors of both S-pores and H-pores can be related to the vacancy formation and diffusion during heat treatment.

Development of a unified constitutive model for an isotropic nickel base superalloy Rene 80

NASA Technical Reports Server (NTRS)

Ramaswamy, V. G.; Vanstone, R. H.; Laflen, J. H.; Stouffer, D. C.

1988-01-01

Accurate analysis of stress-strain behavior is of critical importance in the evaluation of life capabilities of hot section turbine engine components such as turbine blades and vanes. The constitutive equations used in the finite element analysis of such components must be capable of modeling a variety of complex behavior exhibited at high temperatures by cast superalloys. The classical separation of plasticity and creep employed in most of the finite element codes in use today is known to be deficient in modeling elevated temperature time dependent phenomena. Rate dependent, unified constitutive theories can overcome many of these difficulties. A new unified constitutive theory was developed to model the high temperature, time dependent behavior of Rene' 80 which is a cast turbine blade and vane nickel base superalloy. Considerations in model development included the cyclic softening behavior of Rene' 80, rate independence at lower temperatures and the development of a new model for static recovery.

Quantitative experimental determination of the solid solution hardening potential of rhenium, tungsten and molybdenum in single-crystal nickel-based superalloys

DOE PAGES

Fleischmann, Ernst; Miller, Michael K.; Affeldt, Ernst; ...

2015-01-31

Here, the solid-solution hardening potential of the refractory elements rhenium, tungsten and molybdenum in the matrix of single-crystal nickel-based superalloys was experimentally quantified. Single-phase alloys with the composition of the nickel solid-solution matrix of superalloys were cast as single crystals, and tested in creep at 980 °C and 30–75 MPa. The use of single-phase single-crystalline material ensures very clean data because no grain boundary or particle strengthening effects interfere with the solid-solution hardening. This makes it possible to quantify the amount of rhenium, tungsten and molybdenum necessary to reduce the creep rate by a factor of 10. Rhenium is moremore » than two times more effective for matrix strengthening than either tungsten or molybdenum. The existence of rhenium clusters as a possible reason for the strong strengthening effect is excluded as a result of atom probe tomography measurements. If the partitioning coefficient of rhenium, tungsten and molybdenum between the γ matrix and the γ' precipitates is taken into account, the effectiveness of the alloying elements in two-phase superalloys can be calculated and the rhenium effect can be explained.« less

Thermophysical and Mechanical Properties of Advanced Single Crystalline Co-base Superalloys

NASA Astrophysics Data System (ADS)

Volz, N.; Zenk, C. H.; Cherukuri, R.; Kalfhaus, T.; Weiser, M.; Makineni, S. K.; Betzing, C.; Lenz, M.; Gault, B.; Fries, S. G.; Schreuer, J.; Vaßen, R.; Virtanen, S.; Raabe, D.; Spiecker, E.; Neumeier, S.; Göken, M.

2018-05-01

A set of advanced single crystalline γ' strengthened Co-base superalloys with at least nine alloying elements (Co, Ni, Al, W, Ti, Ta, Cr, Si, Hf, Re) has been developed and investigated. The objective was to generate multinary Co-base superalloys with significantly improved properties compared to the original Co-Al-W-based alloys. All alloys show the typical γ/γ' two-phase microstructure. A γ' solvus temperature up to 1174 °C and γ' volume fractions between 40 and 60 pct at 1050 °C could be achieved, which is significantly higher compared to most other Co-Al-W-based superalloys. However, higher contents of Ti, Ta, and the addition of Re decrease the long-term stability. Atom probe tomography revealed that Re does not partition to the γ phase as strongly as in Ni-base superalloys. Compression creep properties were investigated at 1050 °C and 125 MPa in <001> direction. The creep resistance is close to that of first generation Ni-base superalloys. The creep mechanisms of the Re-containing alloy was further investigated and it was found that the deformation is located preferentially in the γ channels although some precipitates are sheared during early stages of creep. The addition of Re did not improve the mechanical properties and is therefore not considered as a crucial element in the design of future Co-base superalloys for high temperature applications. Thermodynamic calculations describe well how the alloying elements influence the transformation temperatures although there is still an offset in the actual values. Furthermore, a full set of elastic constants of one of the multinary alloys is presented, showing increased elastic stiffness leading to a higher Young's modulus for the investigated alloy, compared to conventional Ni-base superalloys. The oxidation resistance is significantly improved compared to the ternary Co-Al-W compound. A complete thermal barrier coating system was applied successfully.

Homogenization kinetics of a nickel-based superalloy produced by powder bed fusion laser sintering

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhang, Fan; Levine, Lyle E.; Allen, Andrew J.

2017-04-01

Additively manufactured (AM) metal components often exhibit fine dendritic microstructures and elemental segregation due to the initial rapid solidification and subsequent melting and cooling during the build process, which without homogenization would adversely affect materials performance. In this letter, we report in situ observation of the homogenization kinetics of an AM nickel-based superalloy using synchrotron small angle X-ray scattering. The identified kinetic time scale is in good agreement with thermodynamic diffusion simulation predictions using microstructural dimensions acquired by ex situ scanning electron microscopy. These findings could serve as a recipe for predicting, observing, and validating homogenization treatments in AM materials.

Homogenization Kinetics of a Nickel-based Superalloy Produced by Powder Bed Fusion Laser Sintering.

PubMed

Zhang, Fan; Levine, Lyle E; Allen, Andrew J; Campbell, Carelyn E; Lass, Eric A; Cheruvathur, Sudha; Stoudt, Mark R; Williams, Maureen E; Idell, Yaakov

2017-04-01

Additively manufactured (AM) metal components often exhibit fine dendritic microstructures and elemental segregation due to the initial rapid solidification and subsequent melting and cooling during the build process, which without homogenization would adversely affect materials performance. In this letter, we report in situ observation of the homogenization kinetics of an AM nickel-based superalloy using synchrotron small angle X-ray scattering. The identified kinetic time scale is in good agreement with thermodynamic diffusion simulation predictions using microstructural dimensions acquired by ex situ scanning electron microscopy. These findings could serve as a recipe for predicting, observing, and validating homogenization treatments in AM materials.

The Effect of Alloying on Topologically Close Packed Phase Instability in Advanced Nickel-Based Superalloy Rene N6

NASA Technical Reports Server (NTRS)

Ritzert, Frank; Arenas, David; Keller, Dennis; Vasudevan, Vijay

1998-01-01

An investigation was conducted to describe topologically close packed (TCP) phase instability as a function of composition in the advanced Ni-base superalloy Rene N6. TCP phases are detrimental to overall high-temperature performance of Ni-base superalloys because of their brittle nature and because they deplete the Ni-rich matrix of potent solid solution strengthening elements. Thirty-four variations of polycrystalline Rene N6 determined from a design-of-experiments approach were cast and homogenized at 1315"C for 80 hours followed by exposure at 10930C for 400 hours to promote TCP formation. The alloys had the following composition ranges in atomic percent: Co 10.61 to 16.73%, Mo 0.32 to 1.34%, W 1.85 to 2.52%, Re 1.80 to 2.1 1 %, Ta 2.36 to 3.02%, Al 11.90 to 14.75%, and Cr 3.57 to 6.23%. Physical and chemical characteristics of all n-ticrostructures obtained were described using various analytical techniques. From these observations, a mathematical description of TCP occurrence (omega and P phase) was generated for polycrystalline Rene N6.

Modeling of abnormal mechanical properties of nickel-based single crystal superalloy by three-dimensional discrete dislocation dynamics

NASA Astrophysics Data System (ADS)

Yang, Hui; Li, Zhenhuan; Huang, Minsheng

2014-12-01

Unlike common single crystals, the nickel-based single crystal superalloy shows surprisingly anomalous flow strength (i.e. with the increase of temperature, the yield strength first increases to a peak value and then decreases) and tension-compression (TC) asymmetry. A comprehensive three-dimensional discrete dislocation dynamics (3D-DDD) procedure was developed to model these abnormal mechanical properties. For this purpose, a series of complicated dynamic evolution details of Kear-Wilsdorf (KW) locks, which are closely related to the flow strength anomaly and TC asymmetry, were incorporated into this 3D-DDD framework. Moreover, the activation of the cubic slip system, which is the origin of the decrease in yield strength with increasing temperature at relatively high temperatures, was especially taken into account by introducing a competition criterion between the unlocking of the KW locks and the activation of the cubic slip system. To test our framework, a series of 3D-DDD simulations were performed on a representative volume cell model with a cuboidal Ni3Al precipitate phase embedded in a nickel matrix. Results show that the present 3D-DDD procedure can successfully capture the dynamic evolution of KW locks, the flow strength anomaly and TC asymmetry. Then, the underlying dislocation mechanisms leading to these abnormal mechanical responses were investigated and discussed in detail. Finally, a cyclic deformation of the nickel-based single crystal superalloy was modeled by using the present DDD model, with a special focus on the influence of KW locks on the Bauschinger effect and cyclic softening.

A phenomenological creep model for nickel-base single crystal superalloys at intermediate temperatures

NASA Astrophysics Data System (ADS)

Gao, Siwen; Wollgramm, Philip; Eggeler, Gunther; Ma, Anxin; Schreuer, Jürgen; Hartmaier, Alexander

2018-07-01

For the purpose of good reproduction and prediction of creep deformation of nickel-base single crystal superalloys at intermediate temperatures, a phenomenological creep model is developed, which accounts for the typical γ/γ‧ microstructure and the individual thermally activated elementary deformation processes in different phases. The internal stresses from γ/γ‧ lattice mismatch and deformation heterogeneity are introduced through an efficient method. The strain hardening, the Orowan stress, the softening effect due to dislocation climb along γ/γ‧ interfaces and the formation of < 112> dislocation ribbons, and the Kear–Wilsdorf-lock effect as key factors in the main flow rules are formulated properly. By taking the cube slip in < 110> \\{100\\} slip systems and < 112> \\{111\\} twinning mechanisms into account, the creep behavior for [110] and [111] loading directions are well captured. Without specific interaction and evolution of dislocations, the simulations of this model achieve a good agreement with experimental creep results and reproduce temperature, stress and crystallographic orientation dependences. It can also be used as the constitutive relation at material points in finite element calculations with complex boundary conditions in various components of superalloys to predict creep behavior and local stress distributions.

Phase-contrast x-ray imaging of microstructure and fatigue-crack propagation in single-crystal nickel-base superalloys

NASA Astrophysics Data System (ADS)

Husseini, Naji Sami

Single-crystal nickel-base superalloys are ubiquitous in demanding turbine-blade applications, and they owe their remarkable resilience to their dendritic, hierarchical microstructure and complex composition. During normal operations, they endure rapid low-stress vibrations that may initiate fatigue cracks. This failure mode in the very high-cycle regime is poorly understood, in part due to inadequate testing and diagnostic equipment. Phase-contrast imaging with coherent synchrotron x rays, however, is an emergent technique ideally suited for dynamic processes such as crack initiation and propagation. A specially designed portable ultrasonic-fatigue apparatus, coupled with x-ray radiography, allows real-time, in situ imaging while simulating service conditions. Three contrast mechanisms - absorption, diffraction, and phase contrast - span the immense breadth of microstructural features in superalloys. Absorption contrast is sensitive to composition and crack displacements, and diffraction contrast illuminates dislocation aggregates and crystallographic misorientations. Phase contrast enhances electron-density gradients and is particularly useful for fatigue-crack studies, sensitive to internal crack tips and openings less than one micrometer. Superalloy samples were imaged without external stresses to study microstructure and mosaicity. Maps of rhenium and tungsten concentrations revealed strong segregation to the center of dendrites, as manifested by absorption contrast. Though nominally single crystals, dendrites were misoriented from the bulk by a few degrees, as revealed by diffraction contrast. For dynamic studies of cyclic fatigue, superalloys were mounted in the portable ultrasonic-fatigue apparatus, subjected to a mean tensile stress of ˜50-150 MPa, and cycled in tension to initiate and propagate fatigue cracks. Radiographs were recorded every thousand cycles over the multimillion-cycle lifetime to measure micron-scale crack growth. Crack

A model for life predictions of nickel-base superalloys in high-temperature low cycle fatigue

NASA Technical Reports Server (NTRS)

Romanoski, Glenn R.; Pelloux, Regis M.; Antolovich, Stephen D.

1988-01-01

Extensive characterization of low-cycle fatigue damage mechanisms was performed on polycrystalline Rene 80 and IN100 tested in the temperature range from 871 to 1000 C. Low-cycle fatigue life was found to be dominated by propagation of microcracks to a critical size governed by the maximum tensile stress. A model was developed which incorporates a threshold stress for crack extension, a stress-based crack growth expression, and a failure criterion. The mathematical equivalence between this mechanistically based model and the strain-life low-cycle fatigue law was demonstrated using cyclic stress-strain relationships. The model was shown to correlate the high-temperature low-cycle fatigue data of the different nickel-base superalloys considered in this study.

A nickel base alloy, NASA WAZ-16, with potential for gas turbine stator vane application

NASA Technical Reports Server (NTRS)

Waters, W. J.; Freche, J. C.

1974-01-01

A nickel-base superalloy based on the nickel-aluminum-tungsten system designated WAZ-16 was developed for high strength in the 1095 C (2000 F) to 1205 C (2200 F) range. Its tensile strength at the latter temperature is approximately 186 MN/m2 (27,000 psi). The combination of properties of the alloy suggest that it has potential as a stator vane material in advanced gas turbine engines.

The structure and properties of a nickel-base superalloy produced by osprey atomization-deposition

NASA Astrophysics Data System (ADS)

Bricknell, Rodger H.

1986-04-01

The production of a nickel-base superalloy, René* 80, by the Osprey atomization-deposition process has been investigated. Dense (>99 pct) material with a fine-grained equiaxed microstructure was deposited using either argon or nitrogen as the atomizing gas. Defects present in the material included a chill region at the collector plate interface, entrapped recirculated particles, porosity, and ceramic particles from the melting and dispensing system. In contrast to other rapid solidification techniques, low oxygen pick-ups are noted in the current technique. Tensile strengths above those displayed by castings are found in both nitrogen and argon atomized material, and in both the as-deposited and heat treated conditions. In addition, no profound mid-temperature ductility loss is displayed by this low oxygen material, in contrast to results on other rapidly solidified material with high oxygen contents. These results are explained in terms of oxygen embrittlement. In view of the excellent properties measured, the attractive economics of the process, and the fact that fine control of the gas/metal flow ratio is shown to be unnecessary, it is concluded that atomization-deposition presents an attractive potential production route for advanced alloys.

Effects of silicon on the oxidation, hot-corrosion, and mechanical behavior of two cast nickel-base superalloys

NASA Technical Reports Server (NTRS)

Miner, R. V., Jr.

1977-01-01

Cast specimens of nickel-base superalloys 713C and Mar-M200 with nominal additions of 0, 0.5, and 1 wt% Si were evaluated for oxidation and corrosion resistance, tensile and stress-rupture properties, microstructure, and phase relations. Results are compared with those of an earlier study of the effects of Si in B-1900. Si had similar effects on all three superalloys. It improves oxidation resistance but the improvement in 713C and Mar-M200 was considerably less than in B-1900. Hot-corrosion resistance is also improved somewhat. Si is, however, detrimental to mechanical properties, in particular, rupture strength and tensile ductility. Si has two obvious microstructural effects. It increases the amount of gamma-prime precipitated in eutectic nodules and promotes a Mo(Ni,Si)2 Laves phase in the alloys containing Mo. These microstructural effects do not appear responsible for the degradation of mechanical properties, however.

High-temperature elastic properties of a nickel-based superalloy studied by surface Brillouin scattering

NASA Astrophysics Data System (ADS)

Zhang, X.; Stoddart, P. R.; Comins, J. D.; Every, A. G.

2001-03-01

Surface Brillouin scattering (SBS) has been used to study the thermally induced surface vibrations (phonons) and thereby obtain the elastic properties of the nickel-based superalloy CMSX-4. SBS spectra have been acquired for a range of wavevector directions in the (001) surface in the single-crystal specimen to determine the angular variation of SAW velocities and the nature of the various excitations. Rayleigh and pseudo-surface acoustic waves as well as the details of the Lamb shoulder are studied, and the elastic constants and engineering moduli are determined using different, but self-consistent, methods at ambient and high temperatures. Calculations of the SBS spectra using surface Green function methods are in good agreement with the experimental results.

Fatigue crack propagation of nickel-base superalloys at 650 deg C

NASA Technical Reports Server (NTRS)

Gayda, J.; Gabb, T. P.; Miner, R. V.

1988-01-01

The 650 C fatigue crack propagation behavior of two nickel-base superalloys, Rene 95 and Waspaloy, is studied with particular emphasis placed on understanding the roles of creep, environment, and two key grain boundary alloying additions, boron and zirconium. Comparison of air and vacuum data shows the air environment to be detrimental over a wide range of frequencies for both alloys. More in-depth analysis on Rene 95 shows at lower frequencies, such as 0.02 Hz, failure in air occurs by intergranular, environmentally-assisted creep crack growth, while at higher frequencies, up to 5.0 Hz, environmental interaction are still evident but creep effects are minimized. The effect of B and Zr in Waspaloy is found to be important where environmental and/or creep interactions are presented. In those instances, removal of B and Zr dramatically increases crack growth and it is therefore plausible that effective dilution of these elements may explain a previously observed trend in which crack growth rates increase with decreasing grain size.

Fatigue crack propagation of nickel-base superalloys at 650 deg C

NASA Technical Reports Server (NTRS)

Gayda, J.; Gabb, T. P.; Miner, R. V.

1985-01-01

The 650 C fatigue crack propagation behavior of two nickel-base superalloys, Rene 95 and Waspaloy, is studied with particular emphasis placed on understanding the roles of creep, environment, and two key grain boundary alloying additions, boron and zirconium. Comparison of air and vacuum data shows the air environment to be detrimental over a wide range of frequencies for both alloys. More in-depth analysis on Rene 95 shows at lower frequencies, such as 0.02 Hz, failure in air occurs by intergranular, environmentally-assisted creep crack growth, while at higher frequencies, up to 5.0 Hz, environmental interactions are still evident but creep effects are minimized. The effect of B and Zr in Waspaloy is found to be important where environmental and/or creep interactions are presented. In those instances, removal of B and Zr dramatically increases crack growth and it is therefore plausible that effective dilution of these elements may explain a previously observed trend in which crack growth rates increase with decreasing grain size.

Absence of dynamic strain aging in an additively manufactured nickel-base superalloy.

PubMed

Beese, Allison M; Wang, Zhuqing; Stoica, Alexandru D; Ma, Dong

2018-05-25

Dynamic strain aging (DSA), observed macroscopically as serrated plastic flow, has long been seen in nickel-base superalloys when plastically deformed at elevated temperatures. Here we report the absence of DSA in Inconel 625 made by additive manufacturing (AM) at temperatures and strain rates where DSA is present in its conventionally processed counterpart. This absence is attributed to the unique AM microstructure of finely dispersed secondary phases (carbides, N-rich phases, and Laves phase) and textured grains. Based on experimental observations, we propose a dislocation-arrest model to elucidate the criterion for DSA to occur or to be absent as a competition between dislocation pipe diffusion and carbide-carbon reactions. With in situ neutron diffraction studies of lattice strain evolution, our findings provide a new perspective for mesoscale understanding of dislocation-solute interactions and their impact on work-hardening behaviors in high-temperature alloys, and have important implications for tailoring thermomechanical properties by microstructure control via AM.

Laser Cladding of Ultra-Thin Nickel-Based Superalloy Sheets.

PubMed

Gabriel, Tobias; Rommel, Daniel; Scherm, Florian; Gorywoda, Marek; Glatzel, Uwe

2017-03-10

Laser cladding is a well-established process to apply coatings on metals. However, on substrates considerably thinner than 1 mm it is only rarely described in the literature. In this work 200 µm thin sheets of nickel-based superalloy 718 are coated with a powder of a cobalt-based alloy, Co-28Cr-9W-1.5Si, by laser cladding. The process window is very narrow, therefore, a precisely controlled Yb fiber laser was used. To minimize the input of energy into the substrate, lines were deposited by setting single overlapping points. In a design of experiments (DoE) study, the process parameters of laser power, laser spot area, step size, exposure time, and solidification time were varied and optimized by examining the clad width, weld penetration, and alloying depth. The microstructure of the samples was investigated by optical microscope (OM) and scanning electron microscopy (SEM), combined with electron backscatter diffraction (EBSD) and energy dispersive X-ray spectroscopy (EDX). Similarly to laser cladding of thicker substrates, the laser power shows the highest influence on the resulting clad. With a higher laser power, the clad width and alloying depth increase, and with a larger laser spot area the weld penetration decreases. If the process parameters are controlled precisely, laser cladding of such thin sheets is manageable.

Laser Cladding of Ultra-Thin Nickel-Based Superalloy Sheets

PubMed Central

Gabriel, Tobias; Rommel, Daniel; Scherm, Florian; Gorywoda, Marek; Glatzel, Uwe

2017-01-01

Laser cladding is a well-established process to apply coatings on metals. However, on substrates considerably thinner than 1 mm it is only rarely described in the literature. In this work 200 µm thin sheets of nickel-based superalloy 718 are coated with a powder of a cobalt-based alloy, Co–28Cr–9W–1.5Si, by laser cladding. The process window is very narrow, therefore, a precisely controlled Yb fiber laser was used. To minimize the input of energy into the substrate, lines were deposited by setting single overlapping points. In a design of experiments (DoE) study, the process parameters of laser power, laser spot area, step size, exposure time, and solidification time were varied and optimized by examining the clad width, weld penetration, and alloying depth. The microstructure of the samples was investigated by optical microscope (OM) and scanning electron microscopy (SEM), combined with electron backscatter diffraction (EBSD) and energy dispersive X-ray spectroscopy (EDX). Similarly to laser cladding of thicker substrates, the laser power shows the highest influence on the resulting clad. With a higher laser power, the clad width and alloying depth increase, and with a larger laser spot area the weld penetration decreases. If the process parameters are controlled precisely, laser cladding of such thin sheets is manageable. PMID:28772639

ESCA study of oxidation and hot corrosion of nickel-base superalloys. [Electron Spectroscopy for Chemical Analysis

NASA Technical Reports Server (NTRS)

Smith, S. R.; Carter, W. J., III; Mateescu, G. D.; Kohl, F. J.; Fryburg, G. C.; Stearns, C. A.

1980-01-01

A study of the high-temperature oxidation and Na2SO4-induced hot corrosion of nickel-base superalloys has been accomplished by using ESCA to determine the surface composition of the oxidized or corroded samples. Oxidation was carried out at 900 or 1000 C in slowly flowing O2 for samples of B-1900, NASA-TRW VIA, 713C, and IN-738. Hot corrosion of B-1900 was induced by applying a coating of Na2SO4 to preoxidized samples, then heating to 900 C in slowly flowing O2. For oxidized samples, the predominant type of scale formed by each superalloy showed a marked surface enrichment of Ti. For corroded samples, the transfer of significant amounts of material from the oxide layer to the surface of the salt layer was observed before the onset of rapidly accelerating weight gain. Marked changes in surface composition coincided with the beginning of accelerating corrosion, the most striking of which were a tenfold decrease in the sulfur to sodium ratio and an increase in the Cr(VI) to Cr(III) ratio.

Effect of casting geometry on mechanical properties of two nickel-base superalloys

NASA Technical Reports Server (NTRS)

Johnston, J. R.; Dreshfield, R. L.; Collins, H. E.

1976-01-01

An investigation was performed to determine mechanical properties of two rhenium-free modifications of alloy TRW, and to evaluate the suitability of the alloy for use in a small integrally cast turbine rotor. The two alloys were initially developed using stress rupture properties of specimens machined from solid gas turbine blades. Properties in this investigation were determined from cast to size bars and bars cut from 3.8 by 7.6 by 17.8 cm blocks. Specimens machined from blocks had inferior tensile strength and always had markedly poorer rupture lives than cast to size bars. At 1,000 C the cast to size bars had shorter rupture lives than those machined from blades. Alloy R generally had better properties than alloy S in the conditions evaluated. The results show the importance of casting geometry on mechanical properties of nickel base superalloys and suggest that the geometry of a component can be simulated when developing alloys for that component.

A study of microstructural characteristics and differential thermal analysis of Ni-based superalloys

NASA Technical Reports Server (NTRS)

Aggarwal, M. D.; Lal, R. B.; Oyekenu, Samuel A.; Parr, Richard; Gentz, Stephen

1989-01-01

The objective of this work is to correlate the mechanical properties of the Ni-based superalloy MAR M246(Hf) used in the Space Shuttle Main Engine with its structural characteristics by systematic study of optical photomicrographs and differential thermal analysis. The authors developed a method of predicting the liquidus and solidus temperature of various nickel based superalloys (MAR-M247, Waspaloy, Udimet-41, polycrystalline and single crystals of CMSX-2 and CMSX-3) and comparing the predictions with the experimental differential thermal analysis (DTA) curves using Perkin-Elmer DTA 1700. The method of predicting these temperatures is based on the additive effect of the components dissolved in nickel. The results were compared with the experimental values.

Effect of Crystal Orientation on Analysis of Single-Crystal, Nickel-Based Turbine Blade Superalloys

NASA Technical Reports Server (NTRS)

Swanson, G. R.; Arakere, N. K.

2000-01-01

High-cycle fatigue-induced failures in turbine and turbopump blades is a pervasive problem. Single-crystal nickel turbine blades are used because of their superior creep, stress rupture, melt resistance, and thermomechanical fatigue capabilities. Single-crystal materials have highly orthotropic properties making the position of the crystal lattice relative to the part geometry a significant and complicating factor. A fatigue failure criterion based on the maximum shear stress amplitude on the 24 octahedral and 6 cube slip systems is presented for single-crystal nickel superalloys (FCC crystal). This criterion greatly reduces the scatter in uniaxial fatigue data for PWA 1493 at 1,200 F in air. Additionally, single-crystal turbine blades used in the Space Shuttle main engine high pressure fuel turbopump/alternate turbopump are modeled using a three-dimensional finite element (FE) model. This model accounts for material orthotrophy and crystal orientation. Fatigue life of the blade tip is computed using FE stress results and the failure criterion that was developed. Stress analysis results in the blade attachment region are also presented. Results demonstrate that control of crystallographic orientation has the potential to significantly increase a component's resistance to fatigue crack growth without adding additional weight or cost.

Superalloy material with improved weldability

DOEpatents

Allen, David B.; Wagner, Gregg P.; Seth, Brij B.

2004-02-24

A fusion weldable superalloy containing 0.005-0.5 wt. % scandium. In one embodiment, the superalloy may have a composition similar to IN-939 alloy, but having added scandium and having only 0.005-0.040 wt. % zirconium. A gas turbine component may be formed by an investment casting of such a scandium-containing superalloy, and may include a fusion weld repaired area. A scandium-containing nickel-based superalloy coated with an MCrAlY bond coat will have improved cyclic oxidation resistance due to the sulfur-gettering effect of the scandium.

Elevated temperature mechanical behavior of new low CTE superalloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cowen, C.J.; Jablonski, P.D.

This paper presents the high temperature mechanical properties of several experimental low coefficient of thermal expansion (CTE) alloys. The use of such alloys facilitate the extension of advanced ferritic stainless steels to higher use temperature in advanced power generation systems. We find that one of these alloys, J5 appears to be favorable for bridging ferritic alloys (operating up to ~600°C) to traditional nickel based superalloys (operating at 750°C).

High temperature low-cycle fatigue mechanisms in single crystals of nickel-based superalloy Mar-M 200

NASA Technical Reports Server (NTRS)

Milligan, W. W.; Jayaraman, N.

1984-01-01

Twenty three high temperature low-cycle fatigue tests were conducted on single crystals of the nickel-based superalloy Mar-M 200. Tests were conducted at 760 and 870 C. SEM fractography and transmission electron microscopy were used to determine mechanisms responsible for the observed orientation dependent fatigue behavior. It has been concluded that the plastic characteristics of the alloy lead to orientation-dependent strain hardening and fatigue lives at 760 C. At 870 C, the elastic characteristics of the alloy dominated the behavior, even though the plastic strain ranges were about the same as they were at 760 C. This led to orientation-dependent fatigue lives, but the trends were not the same as they were at 760 C.

Estimation of the engineering elastic constants of a directionally solidified superalloy for finite element structural analysis

NASA Technical Reports Server (NTRS)

Abdul-Aziz, Ali; Kalluri, Sreeramesh

1991-01-01

The temperature-dependent engineering elastic constants of a directionally solidified nickel-base superalloy were estimated from the single-crystal elastic constants of nickel and MAR-MOO2 superalloy by using Wells' method. In this method, the directionally solidified (columnar-grained) nickel-base superalloy was modeled as a transversely isotropic material, and the five independent elastic constants of the transversely isotropic material were determined from the three independent elastic constants of a cubic single crystal. Solidification for both the single crystals and the directionally solidified superalloy was assumed to be along the (001) direction. Temperature-dependent Young's moduli in longitudinal and transverse directions, shear moduli, and Poisson's ratios were tabulated for the directionally solidified nickel-base superalloy. These engineering elastic constants could be used as input for performing finite element structural analysis of directionally solidified turbine engine components.

Yielding and deformation behavior of the single crystal nickel-base superalloy PWA 1480

NASA Technical Reports Server (NTRS)

Milligan, W. W., Jr.

1986-01-01

Interrupted tensile tests were conducted to fixed plastic strain levels in 100 ordered single crystals of the nickel based superalloy PWA 1480. Testing was done in the range of 20 to 1093 C, at strain rate of 0.5 and 50%/min. The yield strength was constant from 20 to 760 C, above which the strength dropped rapidly and became a stong function of strain rate. The high temperature data were represented very well by an Arrhenius type equation, which resulted in three distinct temperature regimes. The deformation substructures were grouped in the same three regimes, indicating that there was a fundamental relationship between the deformation mechanisms and activation energies. Models of the yielding process were considered, and it was found that no currently available model was fully applicable to this alloy. It was also demonstrated that the initial deformation mechanism (during yielding) was frequently different from that which would be inferred by examining specimens which were tested to failure.

Secondary orientation effects in a single crystal superalloy under mechanical and thermal loads

NASA Technical Reports Server (NTRS)

Kalluri, Sreeramesh; Abdul-Aziz, Ali; Mcgaw, Michael A.

1991-01-01

The nickel-base single crystal superalloy PWA 1480 is a candidate blading material for the advanced turbopump development program of the SSME. In order to improve thermal fatigue resistance of the turbine blades, the single crystal superalloy PWA 1480 is grown along the low modulus zone axes (001) crystal orientation by a directional solidification process. Since cubic single crystal materials such as PWA 1480 exhibit anisotropic elastic behavior, the stresses developed within the single crystal superalloy due to mechanical and thermal loads are likely to be affected by the exact orientation of the secondary crystallographic direction with respect to the geometry of the turbine blade. The effects of secondary crystal orientation on the elastic response of single crystal PWA 1480 superalloy were investigated.

The influence of primary and secondary orientations on the elastic response of a nickel-base single-crystal superalloy

NASA Technical Reports Server (NTRS)

Abdul-Aziz, Ali; Kalluri, Sreeramesh; Mcgaw, Michael A.

1993-01-01

The influence of primary orientation on the elastic response of a (001)-oriented nickel-base single-crystal superalloy, PWA 1480, was investigated under mechanical, thermal, and combined thermal and mechanical loading conditions using finite element techniques. Elastic stress analyses were performed using the MARC finite element code on a square plate of PWA 1480 material. Primary orientation of the single crystal superalloy was varied in increments of 2 deg, from 0 to 10 deg, from the (001) direction. Two secondary orientations (0 and 45 deg) were considered, with respect to the global coordinate system, as the primary orientation angle was varied. The stresses developed within the single crystal plate were determined for each loading condition. In this paper, the influence of the angular offset between the primary crystal orientation and the loading direction on the elastic stress response of the PWA 1480 plate is presented for different loading conditions. The influence of primary orientation angle, when constrained between the bounds considered, was not found to be as significant as the influence of the secondary orientation angle, which is not typically controlled.

Effects of sigma-phase formation on some mechanical properties of a wrought nickel-base superalloy (IN-100)

NASA Technical Reports Server (NTRS)

Dreshfield, R. L.; Ashbrook, R. L.

1974-01-01

The effect of sigma phase formation on an extruded and forged nickel base superalloy with the composition of the casting alloy IN-100 was studied. By adding only aluminum and titanium to remelt stock, three compositions were produced which had varying propensities for sigma formation. These compositions were given a four step heat treatment and were stress-ruptured or tensile tested. The very sigma prone composition had a shorter rupture life than the sigma-free or moderately sigma prone compositions when tested at 843 and 885 C. Elongation in room temperature tensile tests was considerably lower for the very sigma prone composition than for the other two wrought compositions after prolonged exposure at 732 or 843 C.

Hot corrosion studies of four nickel-base superalloys - B-1900, NASA-TRW VIA, 713C and IN738

NASA Technical Reports Server (NTRS)

Fryburg, G. C.; Kohl, F. J.; Stearns, C. A.

1976-01-01

The susceptibility to hot corrosion of four nickel-base superalloys has been studied at 900 and 1000 C in one atmosphere of slowly flowing oxygen. Hot corrosion was induced by coating the samples with known doses of Na2SO4 and oxidizing the coated samples isothermally on a sensitive microbalance. In order of decending susceptibility to hot corrosion, these alloys were ranked: B-1900, 713C, NASA-TRW VIA, IN738. This order corresponds to the order of decreasing molybdenum content of the alloys. Chemical evidence for B-1900 indicates that hot corrosion is instigated by acid fluxing of the protective Al2O3 coating by MoO3.

Effects of convection patterns on freckle formation of directionally solidified Nickel-based superalloy casting with abruptly varying cross-sections

NASA Astrophysics Data System (ADS)

Qin, Ling; Shen, Jun; Li, Qiudong; Shang, Zhao

2017-05-01

The effects of convection patterns on freckle formation of directionally solidified Nickel-based superalloy sample with abruptly varying cross-sections were investigated experimentally and numerically. The experimental results demonstrate that freckles were only observed at the bottom of larger cross-section. Numerical results indicate that this phenomenon should be attributed to the different convection patterns at front of solidification interface. As the withdrawal rate increased, the primary dendrites spacing has an obvious influence on freckle formation. A more in-depth investigation of the convection patterns can provide a better understanding of freckle formation and perhaps offer methods to minimize freckles in turbine blades.

Microstructural development and segregation effects in directionally solidified nickel-based superalloy PWA 1484

NASA Astrophysics Data System (ADS)

Li, Lichun

2002-09-01

These studies were performed to investigate the effects of thermal gradient (G) and growth velocity (V) on the microstructure development and solidification behavior of directionally solidified nickel-based superalloy PWA 1484. Directional solidification (DS) experiments were conducted using a Bridgman crystal growth facility. The solidification velocity ranged from 0.00005 to 0.01 cm/sec and thermal gradients ranged from 12 to 108°C/cm. The as-cast microstructures of DS samples were characterized by using conventional metallography; chemical composition and segregation of directionally solidified samples were analyzed with energy dispersive spectroscopy in SEM. A range of aligned solidification microstructures is exhibited by the alloy when examined as-cast at room temperature: dendrites, flanged cells, cells. The microstructure transitions from cellular to dendritic as the growth velocity increases. The experimental data for PWA1484 exhibits excellent agreement with the well-known exponential equation (lambda1 ∝ G -1/2V-1/4). However, the constant of proportionality is different depending upon the solidification microstructure: (1) dendritic growth with secondary arms leads to a marked dependence of lambda1 on G-1/2 V-1/4; (2) flanged cellular growth with no secondary arms leads to much lower dependence of lambda 1 on G-1/2V -1/4. The primary dendritic arm spacing results were also compared to recent theoretical models. The model of Hunt and Lu and the model of Ma and Sahm provided excellent agreement at medium to high thermal gradients and a wide range of solidification velocities. The anomalous behavior of lambda 1 with high growth velocity V at low G is analyzed based on the samples' microstructures. Off-axis heat flows were shown to cause radial non-uniformity in the dendrite arm spacing data for low thermal gradients and large withdrawal velocities. Various precipitates including gamma', (gamma ' + gamma) eutectic pool or divorced eutectic gamma ', and

TOPSIS based parametric optimization of laser micro-drilling of TBC coated nickel based superalloy

NASA Astrophysics Data System (ADS)

Parthiban, K.; Duraiselvam, Muthukannan; Manivannan, R.

2018-06-01

The technique for order of preference by similarity ideal solution (TOPSIS) approach was used for optimizing the process parameters of laser micro-drilling of nickel superalloy C263 with Thermal Barrier Coating (TBC). Plasma spraying was used to deposit the TBC and a pico-second Nd:YAG pulsed laser was used to drill the specimens. Drilling angle, laser scan speed and number of passes were considered as input parameters. Based on the machining conditions, Taguchi L8 orthogonal array was used for conducting the experimental runs. The surface roughness and surface crack density (SCD) were considered as the output measures. The surface roughness was measured using 3D White Light Interferometer (WLI) and the crack density was measured using Scanning Electron Microscope (SEM). The optimized result achieved from this approach suggests reduced surface roughness and surface crack density. The holes drilled at an inclination angle of 45°, laser scan speed of 3 mm/s and 400 number of passes found to be optimum. From the Analysis of variance (ANOVA), inclination angle and number of passes were identified as the major influencing parameter. The optimized parameter combination exhibited a 19% improvement in surface finish and 12% reduction in SCD.

Studies on the hot corrosion of a nickel-base superalloy, Udimet 700

NASA Technical Reports Server (NTRS)

Misra, A. K.

1984-01-01

The hot corrosion of a nickel-base superalloy, Udimet 700, was studied in the temperature range of 884 to 965 C and with different amounts of Na2SO4. Two different modes of degradation were identified: (1) formation of Na2MoO4 - MoO3 melt and fluxing by this melt, and (2) formation of large interconnected sulfides. The dissolution of Cr2O3, TiO2 in the Na2SO4 melt does not play a significant role in the overall corrosion process. The conditions for the formation of massive interconnected sulfides were identified and a mechanism of degradation due to sulfide formation is described. The formation of Ns2MoO4 - MoO3 melt requires an induction period and various physiochemical processes during the induction period were identified. The factors affecting the length of the induction period were also examined. The melt penetration through the oxide appears to be the prime mode of degradation whether the degradation is due to the formation of sulfides or the formation of the Na2MoO4 - MoO3 melt.

Effects of composition and testing conditions on oxidation behavior of four cast commercial nickel-base superalloys

NASA Technical Reports Server (NTRS)

Lowell, C. E.; Probst, H. B.

1974-01-01

Four cast nickel-base superalloys were oxidized at 1000 and 1100 C for times up to 100 hr in static air and a Mach 1 gas stream. The oxidation resistance was judged by weight change, metal thickness loss, depletion-zone formation, and oxide formation and morphology. The alloys which formed mostly nickel aluminate (NiAl2O4) and aluminum oxide (Al2O3) (B-1900, VIA, and to a lesser extent 713C) were more oxidation resistant. Poorer oxidation resistance was associated with the appearance of chromium sesquioxide (Cr2O3) and chromite spinel (738X). Refractory metal content had little effect on oxidation resistance. Refractory metals appeared in the scale as tapiolite (NiM2O6, where M represents the refractory metal). Thermal cycling in static air appeared to supply sufficient data for the evaluation of oxidation resistance, especially for alloys which form oxides of low volatility. For alloys of higher chromium levels with high propensities toward forming a chromium-bearing scale of higher volatility, testing under conditions of high gas velocity is necessary to assess fully the behavior of the alloy.

Compositional Effects on Nickel-Base Superalloy Single Crystal Microstructures

NASA Technical Reports Server (NTRS)

MacKay, Rebecca A.; Gabb, Timothy P.; Garg,Anita; Rogers, Richard B.; Nathal, Michael V.

2012-01-01

Fourteen nickel-base superalloy single crystals containing 0 to 5 wt% chromium (Cr), 0 to 11 wt% cobalt (Co), 6 to 12 wt% molybdenum (Mo), 0 to 4 wt% rhenium (Re), and fixed amounts of aluminum (Al) and tantalum (Ta) were examined to determine the effect of bulk composition on basic microstructural parameters, including gamma' solvus, gamma' volume fraction, volume fraction of topologically close-packed (TCP) phases, phase chemistries, and gamma - gamma'. lattice mismatch. Regression models were developed to describe the influence of bulk alloy composition on the microstructural parameters and were compared to predictions by a commercially available software tool that used computational thermodynamics. Co produced the largest change in gamma' solvus over the wide compositional range used in this study, and Mo produced the largest effect on the gamma lattice parameter and the gamma - gamma' lattice mismatch over its compositional range, although Re had a very potent influence on all microstructural parameters investigated. Changing the Cr, Co, Mo, and Re contents in the bulk alloy had a significant impact on their concentrations in the gamma matrix and, to a smaller extent, in the gamma' phase. The gamma phase chemistries exhibited strong temperature dependencies that were influenced by the gamma and gamma' volume fractions. A computational thermodynamic modeling tool significantly underpredicted gamma' solvus temperatures and grossly overpredicted the amount of TCP phase at 982 C. Furthermore, the predictions by the software tool for the gamma - gamma' lattice mismatch were typically of the wrong sign and magnitude, but predictions could be improved if TCP formation was suspended within the software program. However, the statistical regression models provided excellent estimations of the microstructural parameters based on bulk alloy composition, thereby demonstrating their usefulness.

Hot corrosion studies of four nickel-base superalloys: B-1900, NASA-TRW VIA, 713C and IN738

NASA Technical Reports Server (NTRS)

Fryburg, G. C.; Kohl, F. J.; Stearns, C. A.

1976-01-01

The susceptibility to hot corrosion of four nickel base superalloys has been studied at 900 deg and 1000 deg C in one atmosphere of slowly flowing oxygen. Hot corrosion was induced by coating the samples with known doses of NaSO4 and oxidizing the coated samples isothermally on a sensitive microbalance. In general, the order of susceptibility found was: B-1900 is greater than 713C is greater than NASA-TRW VIA and is greater than IN738. This order corresponds to the order of decreasing molybdenum content of the alloys. Chemical evidence for B-1900 indicates that hot corrosion is instigated by acid fluxing of the protective Al2O3 coating by MoO3.

Oxidation of a Commercial Nickel-Based Superalloy under Static Loading

NASA Astrophysics Data System (ADS)

Foss, B. J.; Hardy, M. C.; Child, D. J.; McPhail, D. S.; Shollock, B. A.

2014-12-01

The current demands of the aviation industry for increased gas-turbine efficiency necessitate higher turbine entry temperatures, requiring that alloys exhibit superior oxidation resistance. The synergistic effects of oxidation and mechanical stresses pose a complex issue. The purpose of the current research was to examine the effects of stress on the oxidation and oxygen transport in a commercial nickel-based superalloy. Fine grain RR1000 in both polished and shot-peened conditions was studied for classic (zero load) and statically loaded conditions using integrated two-stage isotopic tracing combined with focused-ion-beam secondary ion mass spectrometry (FIB-SIMS). Cr2O3 external oxide formed with semicontinuous TiO2 above and below. Preferential grain boundary Al2O3 internal oxide formation, γ'-dissolution, and recrystallization occurred subsurface. Oxidation mechanisms were dominated by anionic/cationic growth in the external oxide with inward oxygen transport, initially through the partially unprotective external oxide, then along internal oxide/alloy interfaces. Loading did not influence the oxidation products formed but did bring about expedited oxidation kinetics and changes to the oxide morphology. The oxygen diffusivity D {O/ * } (×10-13 cm2s-1) ranged from 0.39 for the polished alloy to 3.7 for the shot-peened condition under compressive stress. Arguably, the most significant effects took place in the subsurface regions. Increased oxidation kinetics were attributed to the development of fast cation diffusion paths as the alloy deformed by creep.

Hall coefficient measurement for residual stress assessment in precipitation hardened IN718 nickel-base superalloy

NASA Astrophysics Data System (ADS)

Velicheti, Dheeraj; Nagy, Peter B.; Hassan, Waled

2017-02-01

We investigated the feasibility of residual stress assessment based on Hall coefficient measurements in precipitation hardened IN718 nickel-base superalloy. As a first step, we studied the influence of microstructural variations on the galvanomagnetic properties of IN718 nickel-base superalloy. We found that the Hall coefficient of IN718 increases from ≈ 8.0×10-11 m3/C in its fully annealed state of 15 HRC Rockwell hardness to ≈ 9.4×10-11 m3/C in its fully hardened state of 45 HRC. We also studied the influence of cold work, i.e., plastic deformation, at room temperature and found that cold work had negligible effect on the Hall coefficient of fully annealed IN718, but significantly reduced it in hardened states of the material. For example, measurements conducted on fully hardened IN718 specimens showed that the Hall coefficient decreased more or less linearly with cold work from its peak value of ≈ 9.4×10-11 m3/C in its intact state to ≈ 9.0×10-11 m3/C in its most deformed state of 22% plastic strain. We also studied the influence of applied stress and found that elastic strain significantly increases the Hall coefficient of IN718 regardless of the state of hardening. The relative sensitivity of the Hall coefficient to elastic strain was measured as a unitless gauge factor K that is defined as the ratio of the relative change of the Hall coefficient ΔRH/RH divided by the axial strain ɛ = σ/E, where σ is the applied uniaxial stress and E is the Young's modulus of the material. We determined that the galvanomagnetic gauge factor of IN718 is κ ≈ 2.6 - 2.9 depending on the hardness level. Besides the fairly high value of the gauge factor, it is important that it is positive, which means that compressive stress in surface-treated components decreases the Hall coefficient in a similar way as plastic deformation does, therefore the unfortunate cancellation that occurs in fully hardened IN718 in the case of electric conductivity measurements will not

The influence of heat treatment on properties of cold rolled alloyed steel and nickel superalloys sheets used in aircraft industry

NASA Astrophysics Data System (ADS)

Zaba, K.; Dul, I.; Puchlerska, S.

2017-02-01

Superalloys based on nickel and selected steels are widely used in the aerospace industry, because of their excellent mechanical properties, heat resistance and creep resistance. Metal sheets of these materials are plastically deformed and applied, inter alia, to critical components of aircraft engines. Due to their chemical composition these materials are hardly deformable. There are various methods to improve the formability of these materials, including plastic deformation at an elevated or high temperature, or a suitable heat treatment before forming process. The paper presents results of the metal sheets testing after heat treatment. For the research, sheets of two types of nickel superalloys type Inconel and of three types of steel were chosen. The materials were subjected to multivariate heat treatment at different temperature range and time. After this step, mechanical properties were examined according to the metal sheet rolling direction. The results were compared and the optimal type of pre-trial softening heat treatment for each of the materials was determined.

Development study of compositions for advanced wrought nickel-base superalloys

NASA Technical Reports Server (NTRS)

Kent, W. B.

1972-01-01

Using NASA IIb as a base composition, the effects of five key elements (carbon, tungsten, tantalum, aluminum, and hafnium) on resultant properties were investigated in an effort to optimize the composition and derive new wrought high temperature alloys with improved strength characteristics. A total of nineteen compositions were melted, extruded, and rolled to bar stock using thermomechanical processing. Both full and partial solution heat treatments were developed for the compositions. Tensile properties from room temperature to 1800 deg F, stress and creep rupture properties to 1800 deg F, and thermal stability characteristics were evaluated. NASA IIb-7 exhibited the best response to the partial solution heat treatment for optimum properties up to 1200 deg F. The alloy contained 0.13C, 9.0 Cr, 9.0 Co, 2.0 Mo, 7.5 W, 10.0 Ta, 3.5 Al, 0.75 Ti, 0.02 B, 0.10 Zr, 0.50 V, 1.0 Hf, and balance nickel.

Effects of hydrogen annealing, sulfur segregation and diffusion on the cyclic oxidation resistance of superalloys: A review

NASA Astrophysics Data System (ADS)

Smialek, J. L.; Jayne, D. T.; Schaeffer, J. C.; Murphy, W. H.

1994-12-01

This review is based on the phenomenon of improved oxide scale adhesion for desulfurized superalloys. The proposed adhesion mechanism involves sulfur interfacial segregation and scale-metal bond weakening. Sulfur surface segregation on superalloys is examined as a function of temperature and sulfur content, and is related to the classical behavior predicted by the McLean isotherm. Effective desulfurization to less than 1 ppmw can be accomplished by hydrogen annealing and is described by sulfur diffusion kinetics in nickel. Hydrogen annealing results in excellent cyclic oxidation resistance for a number of advanced superalloys. The concept of a critical sulfur content is discussed in terms of practical annealing conditions and section thicknesses.

Effects of hydrogen annealing, sulfur segregation and diffusion on the cyclic oxidation resistance of superalloys: A review

NASA Technical Reports Server (NTRS)

Smialek, J. L.; Jayne, D. T.; Schaeffer, J. C.; Murphy, W. H.

1994-01-01

This review is based on the phenomenon of improved oxide scale adhesion for desulfurized superalloys. The proposed adhesion mechanism involves sulfur interfacial segregation and scale-metal bond weakening. Sulfur surface segregation on superalloys is examined as a function of temperature and sulfur content, and is related to the classical behavior predicted by the McLean isotherm. Effective desulfurization to less than 1 ppmw can be accomplished by hydrogen annealing and is described by sulfur diffusion kinetics in nickel. Hydrogen annealing results in excellent cyclic oxidation resistance for a number of advanced superalloys. The concept of a critical sulfur content is discussed in terms of practical annealing conditions and section thicknesses.

Effects of Hydrogen Annealing, Sulfur Segregation and Diffusion on the Cyclic Oxidation Resistance of Superalloys: a Review

NASA Technical Reports Server (NTRS)

Smialek, J. L.; Jayne, D. T.; Schaeffer, J. C.; Murphy, W. H.

1994-01-01

This review is based on the phenomenon of improved oxide scale adhesion for desulfurized superalloys. The proposed adhesion mechanism involves sulfur interfacial segregation and scale-metal bond weakening. Sulfur surface segregation on superalloys is examined as a function of temperature and sulfur content and related to classical behavior predicted by the McLean isotherm. Effective desulfurization to less than 1 ppmw can be accomplished by hydrogen annealing and is governed by sulfur diffusion kinetics in nickel. Hydrogen annealing results in excellent cyclic oxidation resistance for a number of advanced superalloys. The concept of a critical sulfur content is discussed in terms of practical annealing conditions and section thicknesses.

On the Coupling between Recrystallization and Precipitation Following Hot Deformation in a γ-γ' Nickel-Based Superalloy

NASA Astrophysics Data System (ADS)

Seret, Anthony; Moussa, Charbel; Bernacki, Marc; Bozzolo, Nathalie

2018-06-01

Postdynamic recrystallization and γ' precipitation during cooling from γ' supersolvus temperature after hot compression were studied in the AD730 (AD730 is a trademark of Aubert et Duval Company in Paris, France) γ-γ' nickel-based superalloy. Emphasis was on not only both phenomena as distinct mechanisms but also on their mutual influence in terms of physical mechanisms. The growth of γ' precipitates is hastened in the unrecrystallized grains compared to the recrystallized ones. This could possibly be attributed to the higher dislocation content acting as high-diffusivity paths. Postdynamic recrystallization is not prevented by Smith-Zener pinning of the recrystallization front by the γ' precipitates. Instead, the recrystallization front dissolves γ' precipitates, which then reprecipitate discontinuously or continuously and coherently with the surrounding γ matrix in the recrystallized grains.

Etude des mecanismes de formation des microstructures lors du brasage isotherme de superalliages a base de nickel

NASA Astrophysics Data System (ADS)

Ruiz-Vargas, Jose

This thesis reports theoretical and experimental investigations carried out to understand the mechanisms of microstructure formation during isothermal brazing, produced by brazing Inconel 625 and MC2 nickel-based superalloys with filler metal BNi-2. Firstly, studies were made on pure Ni to interpret microstructure's formation with simplified alloy chemistry. Microstructure formation have been studied when varying time at constant temperature (isothermal kinetics), but also when varying temperature for constant hold time (isochronal kinetics). The chemical composition and crystallography of the present phases have been identified, with the following results : (i) the fraction of dissolved base metal has been found proportional to the initial thickness of the brazing alloy, so that the composition of the liquid remains homogeneous with a precise initial equilibrium composition during the whole brazing process, (ii) the melting of the joint occurs in two steps : at lower temperature, it involves only partially melting, and boron diffusion in pure Ni leads to the precipitation of fine Ni3B borides at the interface ; in a second stage, at higher temperature, melting is complete and thermodynamic equilibrium requires significant dissolution of nickel, which also involves the dissolution of part of borides already formed. Secondly, nickel plating technique was used on Inconel 625 nickel-based superalloy. A thin layer of Ni with varying thickness, has been electrodeposited to observe the gradual dissolution of Inconel and microstructural features formation due to the presence of superalloy alloying elements. It has been observed that the nickel coating does not prevent precipitation in the base metal as boron diffuse rapidly through the coating width. In the intermediate nickel plating width, fragile precipitates of nickel borides have been observed, because the contribution of Inconel alloying elements to the melt was very limited. In absence of nickel plating on the

Preferred growth orientation and microsegregation behaviors of eutectic in a nickel-based single-crystal superalloy

PubMed Central

Ma, Dexin; Bührig-Polaczek, Andreas

2015-01-01

A nickel-based single-crystal superalloy was employed to investigate the preferred growth orientation behavior of the (γ + γ′) eutectic and the effect of these orientations on the segregation behavior. A novel solidification model for the eutectic island was proposed. At the beginning of the eutectic island’s crystallization, the core directly formed from the liquid by the eutectic reaction, and then preferably grew along [100] direction. The crystallization of the eutectic along [110] always lagged behind that in [100] direction. The eutectic growth in [100] direction terminated on impinging the edge of the dendrites or another eutectic island. The end of the eutectic island’s solidification terminates due to the encroachment of the eutectic liquid/solid interface at the dendrites or another eutectic island in [110] direction. The distribution of the alloying elements depended on the crystalline axis. The degree of the alloying elements’ segregation was lower along [100] than [110] direction with increasing distance from the eutectic island’s center. PMID:27877773

Phase transformation strengthening of high-temperature superalloys

PubMed Central

Smith, T. M.; Esser, B. D.; Antolin, N.; Carlsson, A.; Williams, R. E. A.; Wessman, A.; Hanlon, T.; Fraser, H. L.; Windl, W.; McComb, D. W.; Mills, M. J.

2016-01-01

Decades of research has been focused on improving the high-temperature properties of nickel-based superalloys, an essential class of materials used in the hot section of jet turbine engines, allowing increased engine efficiency and reduced CO2 emissions. Here we introduce a new ‘phase-transformation strengthening' mechanism that resists high-temperature creep deformation in nickel-based superalloys, where specific alloying elements inhibit the deleterious deformation mode of nanotwinning at temperatures above 700 °C. Ultra-high-resolution structure and composition analysis via scanning transmission electron microscopy, combined with density functional theory calculations, reveals that a superalloy with higher concentrations of the elements titanium, tantalum and niobium encourage a shear-induced solid-state transformation from the γ′ to η phase along stacking faults in γ′ precipitates, which would normally be the precursors of deformation twins. This nanoscale η phase creates a low-energy structure that inhibits thickening of stacking faults into twins, leading to significant improvement in creep properties. PMID:27874007

Zinc-induced embrittlement in nickel-base superalloys by simulation and experiment

NASA Astrophysics Data System (ADS)

Otis, Richard; Waje, Mahesh; Lindwall, Greta; Jefferson, Tiffany; Lange, Jeremy; Liu, Zi-Kui

2017-09-01

The high cost of Re has driven interest in processes for recovering Re from scrap superalloy parts. In this work thermodynamic modelling is used to study Zn-induced embrittlement of a superalloy and to direct experiments. Treating superalloy powder with Zn vapour reduces the average particle size after milling from approximately ?m to 0.5-10 ?m, vs. ?m for untreated powder. Simulations predict the required treatment time to increase with temperature. Agreement between predictions and experiments suggests that an embrittling liquid forms in less than an hour of Zn vapour treatment between 950-1000 ?C and partial pressures of Zn between 14-34 kPa (2-5 psi).

Development of a Single-Crystal Fifth-Generation Nickel Superalloy

NASA Astrophysics Data System (ADS)

Petrushin, N. V.; Elyutin, E. S.; Visik, E. M.; Golynets, S. A.

2017-11-01

The chemical and phase compositions of a rhenium-ruthenium-containing fifth-generation VZhM8 nickel superalloy, which is intended for single-crystal turbine blades of an aviation engine, are calculated using computer simulation. VZhM8 alloy <001>, <011>, and <111> single crystals are fabricated. The microstructure, the γ/γ' misfit, the segregation coefficients of alloying elements, the dissolution temperature of the γ' phase, and the solidus and liquidus temperatures of the VZhM8 alloy single crystals in the as-cast state and after heat treatment are studied. The temperature-time dependences of the static elastic modulus, the short-term mechanical properties, and the long-term strength of the alloy single crystals are determined

Creep and residual mechanical properties of cast superalloys and oxide dispersion strengthened alloys

NASA Technical Reports Server (NTRS)

Whittenberger, J. D.

1981-01-01

Tensile, stress-rupture, creep, and residual tensile properties after creep testing were determined for two typical cast superalloys and four advanced oxide dispersion strengthened (ODS) alloys. The superalloys examined included the nickel-base alloy B-1900 and the cobalt-base alloy MAR-M509. The nickel-base ODS MA-757 (Ni-16CR-4Al-0.6Y2O3 and the iron-base ODS alloy MA-956 (Fe-20Cr-5Al-0.8Y2O3) were extensively studied, while limited testing was conducted on the ODS nickel-base alloys STCA (Ni-16Cr-4.5Al-2Y2O3) with a without Ta and YD-NiCrAl (Ni-16Cr-5Al-2Y2O3). Elevated temperature testing was conducted from 114 to 1477 K except for STCA and YD-NiCrAl alloys, which were only tested at 1366 K. The residual tensile properties of B-1900 and MAR-M509 are not reduced by prior creep testing (strains at least up to 1 percent), while the room temperature tensile properties of ODS nickel-base alloys can be reduced by small amounts of prior creep strain (less than 0.5 percent). The iron-base ODS alloy MA-956 does not appear to be susceptible to creep degradation at least up to strains of about 0.25 percent. However, MA-956 exhibits unusual creep behavior which apparently involves crack nucleation and growth.

Mechanical Behavior of Three-Dimensional Braided Nickel-Based Superalloys Synthesized via Pack Cementation

NASA Astrophysics Data System (ADS)

Lippitz, Nicolas; Erdeniz, Dinc; Sharp, Keith W.; Dunand, David C.

2018-03-01

Braided tubes of Ni-based superalloys are fabricated via three-dimensional (3-D) braiding of ductile Ni-20Cr (wt pct) wires followed by post-textile gas-phase alloying with Al and Ti to create, after homogenization and aging, γ/ γ' strengthened lightweight, porous structures. Tensile tests reveal an increase in strength by 100 MPa compared to as-braided Ni-20Cr (wt pct). An interrupted tensile test, combined with X-ray tomographic scans between each step, sheds light on the failure behavior of the braided superalloy tubes.

Experimental Design for Evaluation of Co-extruded Refractory Metal/Nickel Base Superalloy Joints

DOE Office of Scientific and Technical Information (OSTI.GOV)

ME Petrichek

2005-12-16

not exceed a critical thickness (0.0005 in.). A diffusion barrier that exceeded this thickness would likely fail. The joint fabrication method must therefore mechanically bond the two materials causing little or no interdiffusion upon formation. Co-extrusion fits this description since it forms a mechanical joint between two materials by using heat and pressure. The two materials to be extruded are first assembled and sealed within a co-extrusion billet which is subsequently heated and then extruded through a die. For a production application, once the joint is formed, it is dejacketed to remove the outer canister. The remaining piece consists of two materials bonded together with a thin diffusion barrier. Therefore, the long-term stability of the joint is determined primarily by the kinetics of interdiffusion reaction between the two materials. An experimental design for co-extrusion of refractory metals and nickel-based superalloys was developed to evaluate this joining process and determine the long-term stability of the joints.« less

Effect of hydrogen on deformation structure and properties of CMSX-2 nickel-base single-crystal superalloy

NASA Technical Reports Server (NTRS)

Dollar, M.; Bernstein, I. M.; Walston, S.; Prinz, F.; Domnanovich, A.

1987-01-01

Material used in this study was a heat of the alloy CMSX-2. This nickel-based superalloy was provided in the form of oriented single crystals, solutionized for 3 hrs at 1315 C. It was then usually heat treated as follows: 1050 C/16h/air cool + 850 C/48h/air cool. The resulting microstructure is dominated by cuboidal, ordered gamma precipitates with a volume fraction of about 75% and an average size of 0.5 microns. In brief, the most compelling hydrogen induced-changes in deformation structure are: (1) enhanced dislocation accumulation in the gamma matrix; and (2) more extensive cross-slip of superdislocations in the gamma precipitates. The enhanced dislocation density in gamma acts to decrease the mean free path of a superdislocation, while easier cross slip hinders superdislocation movement by providing pinning points in the form of sessile jobs. Both processes contribute to the increase of flow stress and the notable work hardening that occurs prior to fracture.

Effect of Heat Treatment on Chemical Segregation in CMSX-4 Nickel-Base Superalloy

NASA Astrophysics Data System (ADS)

Szczotok, A.; Chmiela, B.

2014-08-01

Superalloys display a strong tendency toward chemical segregation during solidification. Therefore, it is of great importance to develop appropriate techniques for the melting and casting of superalloys. Elements partitioning between the γ and γ' phases in single crystal superalloys have been investigated by several authors using electron probe microanalysis (Hemmersmeier and Feller-Kniepmeier Mater Sci Eng A 248:87-97, 1998; Kearsey et al. Intermetallics 12:903-910, 2004; Kearsey et al. Superalloys 2004, pp 801-810, 2004; D'Souza et al. Mater Sci Eng A 490:258-265, 2008). We examined the effect of the particular stages of standard heat treatment (solution treatment and ageing) applied to CMSX-4 single crystal superalloy on chemical segregation that occurs between dendrites and interdendritic areas. Dendritic structures were observed using a scanning electron microscope. Analyses of the chemical composition were performed using energy dispersive x-ray spectroscopy. The obtained qualitative and quantitative results for the concentrations of elements enabled us to confirm the dendritic segregation in as-cast CMSX-4 superalloy. The concentrations of some refractory elements (tungsten, rhenium) were much greater in dendrites than in interdendritic areas. However, these differences in chemical composition gradually decreased during heat treatment. The results obtained in this study warrant further examination of the diffusion processes of elements during heat treatment of the investigated superalloy, and of the kinetics of diffusion.

The Cyclic Stress-Strain Behavior of a Single Crystal Nickel-Base Superalloy. Ph.D. Thesis

NASA Technical Reports Server (NTRS)

Gabb, Timothy P.

1988-01-01

The cyclic stress-strain response and similar deformation structures of the single crystal nickel based superalloy was described under a specific set of conditions. The isothermal low cycle fatigue response and deformation structures were described at a typical intermediate temperature and at high temperature. Specimens oriented near the (001) and (111) crystallographic orientations were tested at 1050 C, where more moderate orientation effects were expected. This enabled the description of the deformation structures at each of the 2 temperatures and their relationship to the observed cyclic stress-strain behavior. The initial yield strength of all specimens tested at 650 C was controlled by the shearing of the gamma prime precipitates by dislocation pairs. Low cycle fatigue tests at 650 C had cyclic hardening, which was associated with dislocation interactions in the gamma matrix. The initial yield strength of specimens tested at 1050 C was associated with dislocation bypassing of the gamma prime precipitates. Low cycle fatigue tests at 1050 C had cyclic softening, associated with extensive dislocation recovery at the gamma-gamma prime interfaces along with some gamma prime precipitate coarsening.

Microstructure and Mechanical Properties of Laser Welded Joints of DZ125L and IN718 Nickel Base Superalloys

NASA Astrophysics Data System (ADS)

Liang, Taosha; Wang, Lei; Liu, Yang; Song, Xiu

2018-05-01

The microstructure and mechanical properties of the laser welded joint of DZ125L and IN718 nickel base superalloys were investigated. The results show that the fusion zone (FZ) mainly consists of fine dendrite structure with fine γ', Laves phases and MC carbides inhomogeneously distributed. The high welding temperature induces the partial dissolution of γ' in the heat-affected zone (HAZ) of DZ125L and liquation of grain boundaries in both of the HAZs. After post-weld heat treatment (PWHT), fine γ″ and γ' phases precipitate in the FZ, IN718 HAZ and IN718 base metal (BM), and fine γ' precipitate in the γ channel of the HAZ and BM of DZ125L. With tensile testing, the joints after PWHT show higher strengths than that of the weaker DZ125L alloy. Plastic deformation mainly concentrates in the weaker DZ125L and the joint finally fails in the DZ125L BM.

Effect of hot isostatic pressing on the structure and properties of cast polycrystalline gas-turbine blades made of nickel superalloys

NASA Astrophysics Data System (ADS)

Beresnev, A. G.

2012-05-01

A concept of a two-stage hot isostatic pressing (HIP) cycle is developed for castings made of nickel superalloys in order to minimize plastic deformation and the recrystallization ability of their structure. At the first stage of the cycle, diffusion pore dissolution is predominant due to the motion of vacancies toward grain boundaries in a polycrystal; at the second stage, retained coarse pores are filled during plastic deformation. The effect of uniform compression pressure during HIP and microstructure defects on the vacancy diffusion in nickel superalloys is estimated. A two-stage HIP regime is developed for processing of cast gas-turbine engine blades made of a ZhS6U alloy in order to substantially decrease the shrinkage porosity and to increase the high-temperature characteristics, including the creep and fatigue resistance.

Superalloys with improved weldability for high temperature applications

DOEpatents

Seth, Brij B.; George, Easo P.; Babu, Sudarsanum S.; Goodwin, Gene M.; David, Stanislaus A.; Moyer, Carol E.

2001-01-01

A cast nickel-base superalloy component (10) is made having a composition containing small amounts of both boron and zirconium which are effective in combination to provide increased weldability, where such alloy is adapted for welding by weld (18) to a second superalloy piece, where the two pieces are firmly bonded together and have a Sigmajig transverse stress value (16) greater than 137.9 million Newtons per square meter.

Effects of Exposures on Superalloys for Space Applications

NASA Technical Reports Server (NTRS)

Gabb, Tim; Garg, Anita; Gayda, John

2007-01-01

The industry is demanding longer term service at high temperatures for nickel-base superalloys in gas turbine engine as well as potential space applications. However, longer term service can severely tax alloy phase stability, to the potential detriment of mechanical properties. Cast Mar-M247LC and wrought Haynes 230 superalloys were exposed and creep tested for extended times at elevated temperature. Microstructure and phase evaluations were then undertaken for comparisons.

Review of status and potential of tungsten-wire: Superalloy composites for advanced gas turbine engine blades

NASA Technical Reports Server (NTRS)

Signorelli, R. A.

1972-01-01

The current status of development of refractory-wire-superalloy composites and the potential for their application to turbine blades in land-based power generation and advanced aircraft engines are reviewed. The data indicate that refractory-wire-superalloy composites have application as turbine blades at temperatures of 2200 F and above.

High Temperature Burst Testing of a Superalloy Disk With a Dual Grain Structure

NASA Technical Reports Server (NTRS)

Gayda, J.; Kantzos, P.

2004-01-01

Elevated temperature burst testing of a disk with a dual grain structure made from an advanced nickel-base superalloy, LSHR, was conducted. The disk had a fine grain bore and coarse grain rim, produced using NASA's low cost DMHT technology. The results of the spin testing showed the disk burst at 42 530 rpm in line with predictions based on a 2-D finite element analysis. Further, significant growth of the disk was observed before failure which was also in line with predictions.

Effect of microstructure on high-temperature mechanical behavior of nickel-base superalloys for turbine disc applications

NASA Astrophysics Data System (ADS)

Sharpe, Heather Joan

2007-05-01

Engineers constantly seek advancements in the performance of aircraft and power generation engines, including, lower costs and emissions, and improved fuel efficiency. Nickel-base superalloys are the material of choice for turbine discs, which experience some of the highest temperatures and stresses in the engine. Engine performance is proportional to operating temperatures. Consequently, the high-temperature capabilities of disc materials limit the performance of gas-turbine engines. Therefore, any improvements to engine performance necessitate improved alloy performance. In order to take advantage of improvements in high-temperature capabilities through tailoring of alloy microstructure, the overall objectives of this work were to establish relationships between alloy processing and microstructure, and between microstructure and mechanical properties. In addition, the projected aimed to demonstrate the applicability of neural network modeling to the field of Ni-base disc alloy development and behavior. The first phase of this work addressed the issue of how microstructure varies with heat treatment and by what mechanisms these structures are formed. Further it considered how superalloy composition could account for microstructural variations from the same heat treatment. To study this, four next-generation Ni-base disc alloys were subjected to various controlled heat-treatments and the resulting microstructures were then quantified. These quantitative results were correlated to chemistry and processing, including solution temperature, cooling rate, and intermediate hold temperature. A complex interaction of processing steps and chemistry was found to contribute to all features measured; grain size, precipitate distribution, grain boundary serrations. Solution temperature, above a certain threshold, and cooling rate controlled grain size, while cooling rate and intermediate hold temperature controlled precipitate formation and grain boundary serrations. Diffusion

Strengthening Precipitate Morphologies Fully Quantified in Advanced Disk Superalloys

NASA Technical Reports Server (NTRS)

Gabb, Timothy P.

1998-01-01

Advanced aviation gas turbine engines will require disk superalloys that can operate at higher temperatures and stresses than current conditions. Such applications will be limited by the tensile, creep, and fatigue mechanical properties of these alloys. These mechanical properties vary with the size, shape, and quantity of the gamma precipitates that strengthen disk superalloys. It is therefore important to quantify these precipitate parameters and relate them to mechanical properties to improve disk superalloys. Favorable precipitate morphologies and practical processing approaches to achieve them can then be determined. A methodology has been developed at the NASA Lewis Research Center to allow the comprehensive quantification of the size, shape, and quantity of all types of gamma precipitates.

Effect of Notches on Creep-Fatigue Behavior of a P/M Nickel-Based Superalloy

NASA Technical Reports Server (NTRS)

Telesman, Jack; Gabb, Timothy P.; Ghosn, Louis J.; Gayda, John, Jr.

2015-01-01

A study was performed to determine and model the effect of high temperature dwells on notched low cycle fatigue (NLCF) and notch stress rupture behavior of a fine grain LSHR powder metallurgy (PM) nickel-based superalloy. It was shown that a 90 second dwell applied at the minimum stress (min dwell) was considerably more detrimental to the NLCF lives than similar dwell applied at the maximum stress (max dwell). The short min dwell NLCF lives were shown to be caused by growth of small oxide blisters which caused preferential cracking when coupled with high concentrated notch root stresses. The cyclic max dwell notch tests failed mostly by a creep accumulation, not by fatigue, with the crack origin shifting internally to a substantial distance away from the notch root. The classical von Mises plastic flow model was unable to match the experimental results while the hydrostatic stress profile generated using the Drucker-Prager plasticity flow model was consistent with the experimental findings. The max dwell NLCF and notch stress rupture tests exhibited substantial creep notch strengthening. The triaxial Bridgman effective stress parameter was able to account for the notch strengthening by collapsing the notched and uniform gage geometry test data into a singular grouping.

Optimising mechanical properties of hot forged nickel superalloy 625 components

NASA Astrophysics Data System (ADS)

Singo, Nthambe; Coles, John; Rosochowska, Malgorzata; Lalvani, Himanshu; Hernandez, Jose; Ion, William

2018-05-01

Hot forging and subsequent heat treatment were resulting in substandard mechanical properties of nickel superalloy, Alloy 625, components. The low strength was found to be due to inadequate deformation during forging, excessive grain growth and precipitation of carbides during subsequent heat treatment. Experimentation in a drop forging company and heat treatment facility led to the establishment of optimal parameters to minimise grain size and mitigate the adverse effects of carbide precipitation, leading to successful fulfilment of mechanical property specifications. This was achieved by reducing the number of operations, maximising the extent of deformation by changing the slug dimensions and its orientation in the die, and minimising the time of exposure to elevated temperatures in both the forging and subsequent heat treatment processes to avoid grain growth.

Diffusion welding of MA 6000 and a conventional nickel-base superalloy

NASA Technical Reports Server (NTRS)

Moore, T. J.; Glasgow, T. K.

1985-01-01

A feasibility study of diffusion welding the oxide dispersion strengthened (ODS) alloy MA 6000 to itself and to conventional Ni-base superalloy Udimet 700 was conducted. Butt joints between MA 6000 pieces and lap joints between Udimet 700 and the ODS alloy were produced by hot pressing for 1.25 hr at temperatures ranging from 1000 to 1200 C (1832-2192 F) in vacuum. Following pressing, all weldments were heat treated and machined into mechanical property test specimens. While three different combinations of recrystallized and unrecrystallized MA 6000 butt joints were produced, the unrecrystallized to unrecrystallized joint was most successful as determined by mechanical properties and microstructural examination. Failure to weld the recrystallized material probably related to a lack of adequate deformation at the weld interface. While recrystallized MA 6000 could be diffusion welded to Udimet 700 in places, complete welding over the entire lap joint was not achieved, again due to the lack of sufficient deformation at the faying surfaces. Several methods are proposed to promote the intimate contact necessary for diffusion welding MA 6000 to itself and to superalloys.

Additional thermal fatigue data on nickel- and cobalt-base superalloys, part 1

NASA Technical Reports Server (NTRS)

Howes, M. A. H.

1973-01-01

The fluidized bed technique was used to measure the relative thermal fatigue resistance of twenty-one superalloys. Among the thirty-six variations of composition, solidification method, and surface protection the cycles to cracking differed by two to three orders of magnitude. Some alloys suffered serious weight losses and oxidation. Thermal fatigue data, oxidation, and dimensional changes are reported. The types of superalloys are identified.

Handbook of International alloy Compositions and Designations. Volume II. Superalloys

DTIC Science & Technology

1978-12-01

Offered in Italy 169 Table 12 . Typical Superalloys Offered in Japan 170 Table 13. Typical Superalloys Specified by Sweden 171 Table 14... 12 . Typical Superalloys Offered in Japan Table 13. Typical Superalloys Specified by Sweden Table 14. Typical Superalloys Offered in the Union of...Engineering Properties, INCO Europe Limited, London, England (1976), 12 pp. 8. IN-657 Cast-Nickel-Chromium-Niobium Alloy for Service Against Fuel + Ash

Nanoscale Origins of the Size Effect in the Compression Response of Single Crystal Ni-Base Superalloy Micro-Pillars

PubMed Central

Ying, Siqi; Ma, Lifeng; Papadaki, Chrysanthi; Romano Brandt, Leon; Zhang, Hongjia

2018-01-01

Nickel superalloys play a pivotal role in enabling power-generation devices on land, sea, and in the air. They derive their strength from coherent cuboidal precipitates of the ordered γ’ phase that is different from the γ matrix in composition, structure and properties. In order to reveal the correlation between elemental distribution, dislocation glide and the plastic deformation of micro- and nano-sized volumes of a nickel superalloy, a combined in situ nanoindentation compression study was carried out with a scanning electron microscope (SEM) on micro- and nano-pillars fabricated by focused ion beam (FIB) milling of Ni-base superalloy CMSX4. The observed mechanical response (hardening followed by softening) was correlated with the progression of crystal slip that was revealed using FIB nano-tomography and energy-dispersive spectroscopy (EDS) elemental mapping. A hypothesis was put forward that the dependence of material strength on the size of the sample (micropillar diameter) is correlated with the characteristic dimension of the structural units (γ’ precipitates). By proposing two new dislocation-based models, the results were found to be described well by a new parameter-free Hall–Petch equation. PMID:29621189

Orientation and temperature dependence of some mechanical properties of the single-crystal nickel-base superalloy Rene N4. I - Tensile behavior

NASA Technical Reports Server (NTRS)

Miner, R. V.; Gayda, J.; Gabb, T. P.; Voigt, R. C.

1986-01-01

Single crystal specimens of a nickel-base superalloy with axes near 001, 011, and -112 were tested in tension at room temperature, 760, and 980 C. The alloy Rene N-4, was developed for gas turbine engine blades and has the nominal composition 3.7 Al, 4.2 Ti, 4 Ta, 0.5 Nb, 6 W, 1.5 Mo, 9 Cr, 7.5 Co, balance Ni, (all in weight percent). Analysis of slip band traces, specimen axis rotation, and dislocation Burgers vectors showed that at 760 and 980 C primary cube slip supplanted normal octahedral slip for the -112 line-oriented specimens. The other two orientations, which have lower resolved shear stresses on the cube system, exhibited octahedral slip at all three temperatures. The critical resolved shear stress is considerably greater on the cube system than on the octahedral system at room temperature. However, at 760 and 980 C the critical resolved shear stresses on the two systems are about the same. While the room temperature and 980 C yield strengths for the two orientations exhibiting octahedral slip could be rationalized on the basis of resolved shear stress, those at 760 C could not. Such violations of Schmid's law have previously been observed in other superalloys and single phase gamma-prime.

High strength nickel-base alloy with improved oxidation resistance up to 2200 degrees F

NASA Technical Reports Server (NTRS)

Freche, J. C.; Waters, W. J.

1968-01-01

Modifying the chemistry of the NASA TAZ-8 alloy and utilizing vacuum melting techniques provides a high strength, workable nickel base superalloy with improved oxidation resistance for use up to 2200 degrees F.

A New Approach of Designing Superalloys for Low Density

NASA Technical Reports Server (NTRS)

MacKay, Rebecca A.; Gabb, Timothy P.; Smialek, James L.; Nathal, Michael V.

2010-01-01

New low-density single-crystal (LDS) alloy, have bee. developed for turbine blade applications, which have the potential for significant improvements in the thrust-to-weight ratio over current production superalloys. An innovative alloying strategy was wed to achieve alloy density reductions, high-temperature creep resistance, microstructural stability, and cyclic oxidation resistance. The alloy design relies on molybdenum as a potent. lower-density solid-solution strengthener in the nickel-based superalloy. Low alloy density was also achieved with modest rhenium levels tmd the absence of tungsten. Microstructural, physical mechanical, and environmental testing demonstrated the feasibility of this new LDS superalloy design.

Crystal viscoplasticity model for the creep-fatigue interactions in single-crystal Ni-base superalloy CMSX-8

DOE Office of Scientific and Technical Information (OSTI.GOV)

Estrada Rodas, Ernesto A.; Neu, Richard W.

A crystal viscoplasticity (CVP) model for the creep-fatigue interactions of nickel-base superalloy CMSX-8 is proposed. At the microstructure scale of relevance, the superalloys are a composite material comprised of a γ phase and a γ' strengthening phase with unique deformation mechanisms that are highly dependent on temperature. Considering the differences in the deformation of the individual material phases is paramount to predicting the deformation behavior of superalloys at a wide range of temperatures. In this work, we account for the relevant deformation mechanisms that take place in both material phases by utilizing two additive strain rates to model the deformationmore » on each material phase. The model is capable of representing the creep-fatigue interactions in single-crystal superalloys for realistic 3-dimensional components in an Abaqus User Material Subroutine (UMAT). Using a set of material parameters calibrated to superalloy CMSX-8, the model predicts creep-fatigue, fatigue and thermomechanical fatigue behavior of this single-crystal superalloy. In conclusion, a sensitivity study of the material parameters is done to explore the effect on the deformation due to changes in the material parameters relevant to the microstructure.« less

Crystal viscoplasticity model for the creep-fatigue interactions in single-crystal Ni-base superalloy CMSX-8

DOE PAGES

Estrada Rodas, Ernesto A.; Neu, Richard W.

2017-09-11

A crystal viscoplasticity (CVP) model for the creep-fatigue interactions of nickel-base superalloy CMSX-8 is proposed. At the microstructure scale of relevance, the superalloys are a composite material comprised of a γ phase and a γ' strengthening phase with unique deformation mechanisms that are highly dependent on temperature. Considering the differences in the deformation of the individual material phases is paramount to predicting the deformation behavior of superalloys at a wide range of temperatures. In this work, we account for the relevant deformation mechanisms that take place in both material phases by utilizing two additive strain rates to model the deformationmore » on each material phase. The model is capable of representing the creep-fatigue interactions in single-crystal superalloys for realistic 3-dimensional components in an Abaqus User Material Subroutine (UMAT). Using a set of material parameters calibrated to superalloy CMSX-8, the model predicts creep-fatigue, fatigue and thermomechanical fatigue behavior of this single-crystal superalloy. In conclusion, a sensitivity study of the material parameters is done to explore the effect on the deformation due to changes in the material parameters relevant to the microstructure.« less

Effect of modified mold shell on the microstructure and tensile fracture morphology of single-crystal nickel-base superalloy

NASA Astrophysics Data System (ADS)

Xu, Weitai; Zhao, Yutao; Sun, Shaochun; Liu, Manping; Ma, Dexin; Liang, Xiangfeng; Wang, Cunlong; Tao, Ran

2018-04-01

The mold shell used for single-crystal turbine blades preparation was modified from conventional process to fiber reinforcement technology. The wall thickness was decreased by 32.3 percent (pct) than the conventional process. Then these two mold shells were used to produce single crystal samples of nickel-base superalloy in a Bridgman furnace. The local temperature curves were recorded in the process. The results show that the modified mold shell can increase the temperature gradient in the mushy zone than the conventional mold shell. The primary and secondary dendrite arm space were reduced by 8 pct and 12 pct, respectively. Moreover, both the area fraction and mean size of the γ‧/γ eutectic were declined, as well as the dendritic segregation tendency. Therefore it contributed to the lower residual eutectic and micro-porosity in the heat-treated microstructure. Further, fracture surface of the samples made by modified mold shell exhibited smaller facets and more uniform dimples in the size and shape.

Characterization of Plastic Flow Pertinent to the Evolution of Bulk Residual Stress in Powder-Metallurgy, Nickel-Base Superalloys

NASA Astrophysics Data System (ADS)

Semiatin, S. L.; Fagin, P. N.; Goetz, R. L.; Furrer, D. U.; Dutton, R. E.

2015-09-01

The plastic-flow behavior which controls the formation of bulk residual stresses during final heat treatment of powder-metallurgy (PM), nickel-base superalloys was quantified using conventional (isothermal) stress-relaxation (SR) tests and a novel approach which simulates concurrent temperature and strain transients during cooling following solution treatment. The concurrent cooling/straining test involves characterization of the thermal compliance of the test sample. In turn, this information is used to program the ram-displacement- vs-time profile to impose a constant plastic strain rate during cooling. To demonstrate the efficacy of the new approach, SR tests (in both tension and compression) and concurrent cooling/tension-straining experiments were performed on two PM superalloys, LSHR and IN-100. The isothermal SR experiments were conducted at a series of temperatures between 1144 K and 1436 K (871 °C and 1163 °C) on samples that had been supersolvus solution treated and cooled slowly or rapidly to produce starting microstructures comprising coarse gamma grains and coarse or fine secondary gamma-prime precipitates, respectively. The concurrent cooling/straining tests comprised supersolvus solution treatment and various combinations of subsequent cooling rate and plastic strain rate. Comparison of flow-stress data from the SR and concurrent cooling/straining tests showed some similarities and some differences which were explained in the context of the size of the gamma-prime precipitates and the evolution of dislocation substructure. The magnitude of the effect of concurrent deformation during cooling on gamma-prime precipitation was also quantified experimentally and theoretically.

Temporal Evolution of Nanostructures in a Model Nickel-Base Superalloy: Experiments and Simulations

NASA Technical Reports Server (NTRS)

Sudbrack, Chantal K.; Yoon, Kevin E.; Mao, Zugang; Noebe, Ronald D.; Isheim, Dieter; Seidman, David N.

2003-01-01

The temporal evolution of the nanostructure of a model Ni-base superalloy (Ni-5.2 at.% Al-14.2 at.% Cr) is studied experimentally employing three-dimensional atom-probe (3DAP) microscopy in conjunction with kinetic Monte Carlo (KMC) simulations at 600 C. It is demonstrated that not only can the mean compositions of individual gamma' (Ni3Al with the Li2 structure) precipitates be measured but the Ni, Al, and Cr concentration profiles within the precipitates can also be determined for precipitates with a mean radius () as small as 0.85 nm. The three asymptotic tinie dependencies of the Lifshitz-Slyzov-Wagner (LSW) theory of coarsening (Ostwald ripening) are measured and found to deviate from its theoretical predictions: possible explanations for these discrepancies are discussed. At 0.25 hr. there is 3DAP microscope evidence for the presence of precipitates of another nickel-rich phase. ="Ni3Cr" (Ni3Cr(1-x)Al(x)), which exhibits short-range order (SRO) and that is metastable with respect to Ni3Al. This metastable phase is also found by KMC simulations and has the composition Ni3Cr(1-x)Al(x), which is Ni-2.91 at.% Al-21.98 at.% Cr at 16 hours. Our results demonstrate that the decomposition of gamma the primary gamma (FCC) phase results in the concurrent formation of an ordered phase and a disordered phase by 0.25 hours.

Microstructural Characterization of a Polycrystalline Nickel-Based Superalloy Processed via Tungsten-Intert-Gas-Shaped Metal Deposition

NASA Astrophysics Data System (ADS)

Clark, Daniel; Bache, Martin R.; Whittaker, Mark T.

2010-12-01

Recent trials have produced tungsten-inert-gas (TIG)-welded structures of a suitable scale to allow an evaluation of the technique as an economic and commercial process for the manufacture of complex aeroengine components. The employment of TIG welding is shown to have specific advantages over alternative techniques based on metal inert gas (MIG) systems. Investigations using the nickel-based superalloy 718 have shown that TIG induces a smaller weld pool with less compositional segregation. In addition, because the TIG process involves a pulsed power source, a faster cooling rate is achieved, although this rate, in turn, compromises the deposition rate. The microstructures produced by the two techniques differ significantly, with TIG showing an absence of the detrimental delta and Laves phases typically produced by extended periods at a high temperature using MIG. Instead, an anisotropic dendritic microstructure was evident with a preferred orientation relative to the axis of epitaxy. Niobium was segregated to the interdendritic regions. A fine-scale porosity was evident within the microstructure with a maximum diameter of approximately 5 μm. This porosity often was found in clusters and usually was associated with the interdendritic regions. Subsequent postdeposition heat treatment was shown to have no effect on preexisting porosity and to have a minimal effect on the microstructure.

The effect of hydrogen on the deformation behavior of a single crystal nickel-base superalloy

NASA Technical Reports Server (NTRS)

Walston, W. S.; Thompson, A. W.; Bernstein, I. M.

1989-01-01

The effect of hydrogen on the tensile deformation behavior of PWA 1480 is presented. Tensile tests were interrupted at different plastic strain levels to observe the development of the dislocation structure. Transmission electron microscopy (TEM) foils were cut perpendicular to the tensile axis to allow the deformation of both phases to be simultaneously observed as well as parallel to zone axes (III) to show the superdislocations on their slip planes. Similar to other nickel-base superalloys, hydrogen was detrimental to the room temperature tensile properties of PWA 1480. There was little effect on strength, however the material was severely embrittled. Even without hydrogen, the elongation-to-failure was only approximately 3 percent. The tensile fracture surface was made up primarily of ductile voids with regions of cleavage fracture. These cleavage facets are the eutectic (gamma') in the microstructure. It was shown by quantitative fractography that hydrogen embrittles the eutectic (gamma') and causes the crack path to seek out and fracture through the eutectic (gamma'). There was two to three times the amount of cleavage on the fracture surface of the hydrogen-charged samples than on the surface of the uncharged samples. The effect of hydrogen can also be seen in the dislocation structure. There is a marked tendency for dislocation trapping in the gamma matrix with and without hydrogen at all plastic strain levels. Without hydrogen there is a high dislocation density in the gamma matrix leading to strain exhaustion in this region and failure through the matrix. The dislocation structure at failure with hydrogen is slightly different. The TEM foils cut parallel to zone axes (III) showed dislocations wrapping around gamma precipitates. Zone axes (001) foils show that there is a lower dislocation density in the gamma matrix which can be linked to the effects of hydrogen on the fracture behavior. The primary activity in the gamma precipitates is in the form of

Fretting Stresses in Single Crystal Superalloy Turbine Blade Attachments

NASA Technical Reports Server (NTRS)

Arakere, Nagaraj K.; Swanson, Gregory

2000-01-01

Single crystal nickel base superalloy turbine blades are being utilized in rocket engine turbopumps and turbine engines because of their superior creep, stress rupture, melt resistance and thermomechanical fatigue capabilities over polycrystalline alloys. Currently the most widely used single crystal nickel base turbine blade superalloys are PWA 1480/1493 and PWA 1484. These alloys play an important role in commercial, military and space propulsion systems. High Cycle Fatigue (HCF) induced failures in aircraft gas turbine and rocket engine turbopump blades is a pervasive problem. Blade attachment regions are prone to fretting fatigue failures. Single crystal nickel base superalloy turbine blades are especially prone to fretting damage because the subsurface shear stresses induced by fretting action at the attachment regions can result in crystallographic initiation and crack growth along octahedral planes. Furthermore, crystallographic crack growth on octahedral planes under fretting induced mixed mode loading can be an order of magnitude faster than under pure mode I loading. This paper presents contact stress evaluation in the attachment region for single crystal turbine blades used in the NASA alternate Advanced High Pressure Fuel Turbo Pump (HPFTP/AT) for the Space Shuttle Main Engine (SSME). Single crystal materials have highly orthotropic properties making the position of the crystal lattice relative to the part geometry a significant factor in the overall analysis. Blades and the attachment region are modeled using a large-scale 3D finite element (FE) model capable of accounting for contact friction, material orthotrophy, and variation in primary and secondary crystal orientation. Contact stress analysis in the blade attachment regions is presented as a function of coefficient of friction and primary and secondary crystal orientation, Stress results are used to discuss fretting fatigue failure analysis of SSME blades. Attachment stresses are seen to reach

Analysis of Brazing Effect on Hot Corrosion Behavior of a Nickel-Based Aerospace Superalloy

NASA Astrophysics Data System (ADS)

Esmaeili, N.; Ojo, O. A.

2018-06-01

The effects of brazing and use of composite powder mixture as interlayer material on hot corrosion resistance of brazed IN738 superalloy were studied. Brazing was observed to result in significant reduction in the hot corrosion resistance of the superalloy. However, application of composite powder mixture, which consists of additive superalloy powder, enhanced the hot corrosion resistance of brazed samples. It is also found that although the use of composite powder mixture increased hot corrosion resistance of brazed alloy, if the additive powder completely melts, which is possible during brazing, it can significantly reduce the hot corrosion resistance of the brazed joint. Elemental micro-segregation during solidification of the joint with completely melted powder mixture produces chromium-depleted zones and consequently reduces hot corrosion resistance, since a uniform distribution and adequate chromium concentration are necessary to combat hot corrosion. This has not been previously reported in the literature and it is crucial to the use of composite powder mixture for enhancing the properties of brazed superalloys.

Effect of Environmental Exposures on Fatigue Life of P/M Disk Superalloys

NASA Technical Reports Server (NTRS)

Draper, Susan

2011-01-01

As the temperature capability of Ni-base superalloy powder metallurgy disks is steadily increased, environmental resistance and protection of advanced nickel-based turbine disk components are becoming increasingly important. Localized surface hot corrosion attack and damage from oxidation have been shown to impair disk fatigue life and may eventually limit disk operating temperatures. NASA Research Announcement (NRA) contracts have been awarded to GE Aviation and Honeywell Aerospace to separately develop fatigue resistant metallic and ceramic coatings for corrosion resistance and the corrosion/fatigue results of selected coatings will be presented. The microstructural response of a bare ME3 disk superalloy has been evaluated for moderate (704 C) and aggressive (760-816 C) oxidizing exposures up to 2,020 hours. Cross section analysis reveals sub-surface damage (significant for aggressive exposures) that consists of Al2O3 "fingers", interfacial voids, a recrystallized precipitate-free layer and GB carbide dissolution. The effects of a Nichrome corrosion coating on this microstructural response will also be presented.

3D DDD modelling of dislocation-precipitate interaction in a nickel-based single crystal superalloy under cyclic deformation

NASA Astrophysics Data System (ADS)

Lin, Bing; Huang, Minsheng; Zhao, Liguo; Roy, Anish; Silberschmidt, Vadim; Barnard, Nick; Whittaker, Mark; McColvin, Gordon

2018-06-01

Strain-controlled cyclic deformation of a nickel-based single crystal superalloy has been modelled using three-dimensional (3D) discrete dislocation dynamics (DDD) for both [0 0 1] and [1 1 1] orientations. The work focused on the interaction between dislocations and precipitates during cyclic plastic deformation at elevated temperature, which has not been well studied yet. A representative volume element with cubic γ‧-precipitates was chosen to represent the material, with enforced periodical boundary conditions. In particular, cutting of superdislocations into precipitates was simulated by a back-force method. The global cyclic stress-strain responses were captured well by the DDD model when compared to experimental data, particularly the effects of crystallographic orientation. Dislocation evolution showed that considerably high density of dislocations was produced for [1 1 1] orientation when compared to [0 0 1] orientation. Cutting of dislocations into the precipitates had a significant effect on the plastic deformation, leading to material softening. Contour plots of in-plane shear strain proved the development of heterogeneous strain field, resulting in the formation of shear-band embryos.

Mechanical Properties of a Superalloy Disk with a Dual Grain Structure

NASA Technical Reports Server (NTRS)

Gayda, John; Gabb, Timothy; Kantzos, Peter

2003-01-01

Mechanical properties from an advanced, nickel-base superalloy disk, with a dual grain structure consisting of a fine grain bore and coarse grain rim, were evaluated. The dual grain structure was produced using NASA's low cost Dual Microstructure Heat Treatment (DMHT) process. The results showed the DMHT disk to have a high strength, fatigue resistant bore comparable to a subsolvus (fine grain) heat treated disk, and a creep resistant rim comparable to a supersolvus (coarse grain) heat treated disk. Additional work on subsolvus solutioning before or after the DMHT conversion appears to be a viable avenue for further improvement in disk properties.

The potential for CMCs to replace superalloys in engine exhaust ducts

NASA Astrophysics Data System (ADS)

Roth, Richard; Clark, Joel P.; Field, Frank R.

1994-01-01

The Materials Systems Laboratory at the Massachusetts Institute of Technology has conducted research to develop decision tools that can facilitate materials selection and provide a deeper understanding of the design tradeoffs that occur when choosing among advanced aerospace materials for high-temperature applications. As an illustration of the use of these tools, this paper describes research done to evaluate the material alternatives currently under consideration for exhaust ducts in aircraft gas turbine engines. Although nickel-based superalloys currently prevail for this application, the increasing temperatures of modern engines are necessitating the usage of higher temperature materials.

Microstructural indicators of transition mechanisms in time-dependent fatigue crack growth in nickel base superalloys

NASA Astrophysics Data System (ADS)

Heeter, Ann E.

Gas turbine engines are an important part of power generation in modern society, especially in the field of aerospace. Aerospace engines are design to last approximately 30 years and the engine components must be designed to survive for the life of the engine or to be replaced at regular intervals to ensure consumer safety. Fatigue crack growth analysis is a vital component of design for an aerospace component. Crack growth modeling and design methods date back to an origin around 1950 with a high rate of accuracy. The new generation of aerospace engines is designed to be efficient as possible and require higher operating temperatures than ever seen before in previous generations. These higher temperatures place more stringent requirements on the material crack growth performance under creep and time dependent conditions. Typically the types of components which are subject to these requirements are rotating disk components which are made from advanced materials such as nickel base superalloys. Traditionally crack growth models have looked at high temperature crack growth purely as a function of temperature and assumed that all crack growth was either controlled by a cycle dependent or time dependent mechanism. This new analysis is trying to evaluate the transition between cycle-dependent and time-dependent mechanism and the microstructural markers that characterize this transitional behavior. The physical indications include both the fracture surface morphology as well as the shape of the crack front. The research will evaluate whether crack tunneling occurs and whether it consistently predicts a transition from cycle-dependent crack growth to time-dependent crack growth. The study is part of a larger research program trying to include the effects of geometry, mission profile and environmental effects, in addition to temperature effects, as a part of the overall crack growth system. The outcome will provide evidence for various transition types and correlate those

Copper-nickel superalloys as inert alloy anodes for aluminum electrolysis

NASA Astrophysics Data System (ADS)

Shi, Zhongning; Xu, Junli; Qiu, Zhuxian; Wang, Zhaowen; Gao, Bingliang

2003-11-01

The superalloys Cu-Ni-Al, Cu-Ni-Fe, and Cu-Ni-Cr were studied as anodes for aluminum electrolysis. The alloys were tested for corrosion in acidic electrolyte molten salt and for oxidation in both air and oxygen. The results showed that the Cu-Ni-Al anodes possess excellent resistance to oxidation and corrosion, and the oxidation rates of Cu-Ni-Fe and Cu-Ni-Al anodes were slower than those of pure copper or nickel. During electrolysis, the cell voltage of the Cu-Ni-Al anode was affected most by the concentration of alumina in cryolite molten salt. The Cu-Ni-Fe anode exhibited corrosion resistance in electrolyte molten salt. Comparatively, the Cu-Ni-Cr anode showed poor resistance to oxidation and corrosion. The testing found that further study is warranted on the use of Cu-Ni-Al and Cu-Ni-Fe as inert alloy anodes.

Use of the CSA to Calculate Phase Diagrams and Coherent Inter-Phase Boundary Energies of Multi-Component Nickel-Based Alloys

DTIC Science & Technology

2009-03-02

desirable performance such as their mechanical properties and oxidation-resistance. In this report, we obtain a thermodynamic description of Ni-AI...quaternary system for nickel-based superalloys since the addition of Re improves the mechanical properties of Ni-based superalloys [93Qui], (ii) extensive...well as in solidified samples. 7. Mechanical property Analysis A Micromet II and Macromet II units from Buehler Co. are capable of micro-hardness

Superalloy for high-temperature hydrogen environmental applications

NASA Technical Reports Server (NTRS)

McKannan, Eugene C. (Inventor); McPherson, William B. (Inventor); Ahmed, Shaffiq (Inventor); Chandler, Shirley S. (Inventor)

1991-01-01

A nickel-based superalloy is provided which is resistant to deterioration in hydrogen at high operating temperatures and pressures, and which thus can be used in hydrogen-fueled spacecraft such as the Space Shuttle. The superalloy is characterized by a two-phase microstructure and consists of a gamma-prime precipitated phase in a gamma matrix. The gamma matrix phase is a primary solid solution and the gamma precipitated phase will be an intermetallic compound of the type A.sub.3 B, such as nickel aluminide or titanide. Both phases are coherent, ordered, and compatible, and thus will retain most of their strength at elevated temperatures. The alloy consists essentially of (by weight): Ni 50-60%, Cr 10-20%, Al 2-6%, Co 2-5%, Ti 3-8%, W 5-12%, Mo 5-10%, Nb 1-3%, wherein the ratio W/MO is approximately equal to 1, and Ti/Al ranges from about 1 to about 2.

Evaluation of coatings for cobalt- and nickel-base superalloys, volume 2

NASA Technical Reports Server (NTRS)

Moore, V. S.; Brentnall, W. D.; Stetson, A. R.

1970-01-01

The final results of an oxidation-reduction rig evaluation of aluminide coatings are presented, as applied to 1N-100 and B1900 nickel-base and X-10 and WI-52 cobalt-base alloys. Burner rigs were used which operated on JP-5 fuel and air, producing a gas velocity of 0.85 (2000 to 2500 ft/sec) at the specimen's leading edge. One-hour heating cycles were used with three minutes of air blast cooling. Results of testing at temperatures ranging from T sub max of 1850 to 2050 F indicate that coated B1900 has the longest oxidation life at all temperatures, followed by IN-100X-40WI-52, based on a weight change criterion. Coatings on nickel-base alloys provided more than twice the life of coating on cobalt-base alloys at comparable temperatures. The coatings with higher aluminum content and comparable thickness had longer lives. Silicon appeared to be a beneficial additive in the nickel-base alloy coatings for long term, low temperature life, but not for short term, high temperature performance. Chromium was identified in all coatings. Extrapolating the life results obtained to 1600 F, all the selected coatings on the four alloys would be protective for at least 10,000 hours.

Dendritic microstructure in argon atomized superalloy powders

NASA Technical Reports Server (NTRS)

Tewari, S. N.; Kumar, Mahundra

1986-01-01

The dendritic microstructure of atomized nickel base superalloy powders (Ni-20 pct Cr, NIMONIC-80A, ASTROALOY, and ZHS6-K) was studied. Prealloyed vacuum induction melted ingots were argon-atomized, the powders were cooled to room temperature, and various powder-size fractions were examined by optical metallography. Linear correlations were obtained for the powder size dependence of the secondary dendrite arm spacing, following the expected d-alpha (R) to the m power dependence on the particle size for all four superalloy compositions. However, the Ni-20 pct Cr alloy, which had much coarser arm spacing as compared to the other three alloys, had a much larger value of m.

Nickel-based rechargeable batteries

NASA Astrophysics Data System (ADS)

Shukla, A. K.; Venugopalan, S.; Hariprakash, B.

Nickel-iron (Ni-Fe), nickel-cadmium (Ni-Cd), nickel-hydrogen (Ni-H 2), nickel-metal hydride (Ni-MH) and nickel-zinc (Ni-Zn) batteries employ nickel oxide electrodes as the positive plates, and are hence, categorised as nickel-based batteries. This article highlights the operating principles and advances made in these battery systems during the recent years. In particular, significant improvements have been made in the Ni-MH batteries which are slowly capturing the market occupied by the ubiquitous Ni-Cd batteries.

Exploratory Investigation of Advanced-Temperature Nickel-Base Alloys

NASA Technical Reports Server (NTRS)

Freche, John C.; Waters, William J.

1959-01-01

An investigation was conducted to provide an advanced-temperature nickel-base alloy with properties suitable for aircraft turbine blades as well as for possible space vehicle applications. An entire series of alloys that do not require vacuum melting techniques and that generally provide good stress-rupture and impact properties was evolved. The basic-alloy composition of 79 percent nickel, 8 percent molybdenum, 6 percent chromium, 6 percent aluminum, and 1 percent zirconium was modified by a series of element additions such as carbon, titanium, and boron, with the nickel content adjusted to account for the additives. Stress-rupture, impact, and swage tests were made with all the alloys. The strongest composition (basic alloy plus 1.5 percent titanium plus 0.125 percent carbon) displayed 384- and 574-hour stress-rupture lives at 1800 F and 15,000 psi in the as-cast and homogenized conditions, respectively. All the alloys investigated demonstrated good impact resistance. Several could not be broken in a low-capacity Izod impact tester and, on this basis, all compared favorably with several high-strength high-temperature alloys. Swaging cracks were encountered with all the alloys. In several cases, however, these cracks were slight and could be detected only by zyglo examination. Some of these compositions may become amenable to hot working on further development. On the basis of the properties indicated, it appears that several of the alloys evolved, particularly the 1.5 percent titanium plus 0.125 percent carbon basic-alloy modification, could be used for advanced- temperature turbine blades, as well as for possible space vehicle applications.

Microstructure of selective laser melted CM247LC nickel-based superalloy and its evolution through heat treatment

DOE Office of Scientific and Technical Information (OSTI.GOV)

Divya, V.D., E-mail: dv272@cam.ac.uk; Muñoz-Moreno, R.; Messé, O.M.D.M.

2016-04-15

The selective laser melting of high temperature alloys is of great interest to the aerospace industry as it offers the prospect of producing more complex geometries than can be achieved with other manufacturing methods. In this study, the microstructure of the nickel-based superalloy, CM247LC, has been characterised following selective laser melting and after a post deposition heat treatment below the γ′ solvus temperature. In the as-deposited state, scanning electron microscopy with electron backscatter diffraction revealed a fine, cellular microstructure with preferential alignment of 〈001〉 along the build direction. A high dislocation density was seen at the periphery of the cells,more » indicating substantial localised deformation of the material. Fine primary MC carbides were also observed in the inter-cellular regions. High-resolution transmission electron microscopy identified the occurrence of very fine γ′ precipitates, approximately 5 nm in diameter, dispersed within the gamma phase. After heat treatment, the elongated cell colonies were observed to partially coalesce, accompanied by a decrease in dislocation density, producing columnar grains along the build direction. Cuboidal γ′ precipitates approximately 500 nm in diameter were observed to form in the recrystallised grains, accompanied by larger γ′ precipitates on the grain boundaries.« less

Strain Amount Dependent Grain Size and Orientation Developments during Hot Compression of a Polycrystalline Nickel Based Superalloy

PubMed Central

He, Guoai; Tan, Liming; Liu, Feng; Huang, Lan; Huang, Zaiwang; Jiang, Liang

2017-01-01

Controlling grain size in polycrystalline nickel base superalloy is vital for obtaining required mechanical properties. Typically, a uniform and fine grain size is required throughout forging process to realize the superplastic deformation. Strain amount occupied a dominant position in manipulating the dynamic recrystallization (DRX) process and regulating the grain size of the alloy during hot forging. In this article, the high-throughput double cone specimen was introduced to yield wide-range strain in a single sample. Continuous variations of effective strain ranging from 0.23 to 1.65 across the whole sample were achieved after reaching a height reduction of 70%. Grain size is measured to be decreased from the edge to the center of specimen with increase of effective strain. Small misorientation tended to generate near the grain boundaries, which was manifested as piled-up dislocation in micromechanics. After the dislocation density reached a critical value, DRX progress would be initiated at higher deformation region, leading to the refinement of grain size. During this process, the transformations from low angle grain boundaries (LAGBs) to high angle grain boundaries (HAGBs) and from subgrains to DRX grains are found to occur. After the accomplishment of DRX progress, the neonatal grains are presented as having similar orientation inside the grain boundary. PMID:28772514

Effects of Stress Ratio and Microstructure on Fatigue Failure Behavior of Polycrystalline Nickel Superalloy

NASA Astrophysics Data System (ADS)

Zhang, H.; Guan, Z. W.; Wang, Q. Y.; Liu, Y. J.; Li, J. K.

2018-05-01

The effects of microstructure and stress ratio on high cycle fatigue of nickel superalloy Nimonic 80A were investigated. The stress ratios of 0.1, 0.5 and 0.8 were chosen to perform fatigue tests in a frequency of 110 Hz. Cleavage failure was observed, and three competing failure crack initiation modes were discovered by a scanning electron microscope, which were classified as surface without facets, surface with facets and subsurface with facets. With increasing the stress ratio from 0.1 to 0.8, the occurrence probability of surface and subsurface with facets also increased and reached the maximum value at R = 0.5, meanwhile the probability of surface initiation without facets decreased. The effect of microstructure on the fatigue fracture behavior at different stress ratios was also observed and discussed. Based on the Goodman diagram, it was concluded that the fatigue strength of 50% probability of failure at R = 0.1, 0.5 and 0.8 is lower than the modified Goodman line.

Innovative technologies for powder metallurgy-based disk superalloys: Progress and proposal

NASA Astrophysics Data System (ADS)

Chong-Lin, Jia; Chang-Chun, Ge; Qing-Zhi, Yan

2016-02-01

Powder metallurgy (PM) superalloys are an important class of high temperature structural materials, key to the rotating components of aero engines. In the purview of the present challenges associated with PM superalloys, two novel approaches namely, powder preparation and the innovative spray-forming technique (for making turbine disk) are proposed and studied. Subsequently, advanced technologies like electrode-induction-melting gas atomization (EIGA), and spark-plasma discharge spheroidization (SPDS) are introduced, for ceramic-free superalloy powders. Presently, new processing routes are sought after for preparing finer and cleaner raw powders for disk superalloys. The progress of research in spray-formed PM superalloys is first summarized in detail. The spray-formed superalloy disks specifically exhibit excellent mechanical properties. This paper reviews the recent progress in innovative technologies for PM superalloys, with an emphasis on new ideas and approaches, central to the innovation driving techniques like powder processing and spray forming. Project supported by the National Natural Science Foundation of China (Grant Nos. 50974016 and 50071014).

The interaction of reaction-bonded silicon carbide and inconel 600 with a nickel-based brazing alloy

NASA Astrophysics Data System (ADS)

McDermid, J. R.; Pugh, M. D.; Drew, R. A. L.

1989-09-01

The objective of the present research was to join reaction-bonded silicon carbide (RBSC) to INCONEL 600 (a nickel-based superalloy) for use in advanced heat engine applications using either direct brazing or composite interlayer joining. Direct brazing experiments employed American Welding Society (AWS) BNi-5, a commercial nickel-based brazing alloy, as a filler material; composite interlayers consisted of intimate mixtures of α-SiC and BNi-5 powders. Both methods resulted in the liquid filler metal forming a Ni-Si liquid with the free Si in the RBSC, which, in turn, reacted vigorously with the SiC component of the RBSC to form low melting point constituents in both starting materials and Cr carbides at the metal-ceramic interface. Using solution thermodynamics, it was shown that a Ni-Si liquid of greater than 60 at. pct Ni will decompose a-SiC at the experimental brazing temperature of 1200 ‡C; these calculations are consistent with the experimentally observed composition profiles and reaction morphology within the ceramic. It was concluded that the joining of RBSC to INCONEL 600 using a nickel-based brazing alloy is not feasible due to the inevitability of the filler metal reacting with the ceramic, degrading the high-temperature properties of the base materials.

Predicting the morphologies of γ' precipitates in cobalt-based superalloys

DOE PAGES

Jokisaari, Andrea M.; Naghavi, S. S.; Wolverton, C.; ...

2017-09-06

Cobalt-based alloys with γ/γ' microstructures have the potential to become the next generation of superalloys, but alloy compositions and processing steps must be optimized to improve coarsening, creep, and rafting behavior. While these behaviors are different than in nickel-based superalloys, alloy development can be accelerated by understanding the thermodynamic factors influencing microstructure evolution. In this work, we develop a phase field model informed by first-principles density functional theory and experimental data to predict the equilibrium shapes of Co-Al-W γ' precipitates. Three-dimensional simulations of single and multiple precipitates are performed to understand the effect of elastic and interfacial energy on coarsenedmore » and rafted microstructures; the elastic energy is dependent on the elastic stiffnesses, misfit strain, precipitate size, applied stress, and precipitate spatial distribution. We observe characteristic microstructures dependent on the type of applied stress that have the same γ' morphology and orientation seen in experiments, indicating that the elastic stresses arising from coherent γ/γ' interfaces are important for morphological evolution during creep. Here, the results also indicate that the narrow γ channels between γ' precipitates are energetically favored, and provide an explanation for the experimentally observed directional coarsening that occurs without any applied stress.« less

Fabrication of tungsten wire reinforced nickel-base alloy composites

NASA Technical Reports Server (NTRS)

Brentnall, W. D.; Toth, I. J.

1974-01-01

Fabrication methods for tungsten fiber reinforced nickel-base superalloy composites were investigated. Three matrix alloys in pre-alloyed powder or rolled sheet form were evaluated in terms of fabricability into composite monotape and multi-ply forms. The utility of monotapes for fabricating more complex shapes was demonstrated. Preliminary 1093C (2000F) stress rupture tests indicated that efficient utilization of fiber strength was achieved in composites fabricated by diffusion bonding processes. The fabrication of thermal fatigue specimens is also described.

Feasibility of producing cast-refractory metal-fiber superalloy composites

NASA Technical Reports Server (NTRS)

Mcintyre, R. D.

1973-01-01

A study was conducted to evaluate the feasibility of direct casting as a practical method for producing cast superalloy tungsten or columbium alloy fiber composites while retaining a high percentage of fiber strength. Fourteen nickel base, four cobalt, and three iron based matrices were surveyed for their degree of reaction with the metal fibers. Some stress-rupture results were obtained at temperatures of 760, 816, 871, and 1093 C for a few composite systems. The feasibility of producing acceptable composites of some cast nickel, cobalt, and iron matrix alloys with tungsten or columbium alloy fibers was demonstrated.

Creep deformation mechanism mapping in nickel base disk superalloys

DOE PAGES

Smith, Timothy M.; Unocic, Raymond R.; Deutchman, Hallee; ...

2016-05-10

We investigated the creep deformation mechanisms at intermediate temperature in ME3, a modern Ni-based disk superalloy, using diffraction contrast imaging. Both conventional transmission electron microscopy (TEM) and scanning TEM were utilised. Distinctly different deformation mechanisms become operative during creep at temperatures between 677-815 °C and at stresses ranging from 274 to 724 MPa. Both polycrystalline and single-crystal creep tests were conducted. The single-crystal tests provide new insight into grain orientation effects on creep response and deformation mechanisms. Creep at lower temperatures (≤760 °C) resulted in the thermally activated shearing modes such as microtwinning, stacking fault ribbons and isolated superlattice extrinsicmore » stacking faults. In contrast, these faulting modes occurred much less frequently during creep at 815 °C under lower applied stresses. Instead, the principal deformation mode was dislocation climb bypass. In addition to the difference in creep behaviour and creep deformation mechanisms as a function of stress and temperature, it was also observed that microstructural evolution occurs during creep at 760 °C and above, where the secondary coarsened and the tertiary precipitates dissolved. Based on this work, a creep deformation mechanism map is proposed, emphasising the influence of stress and temperature on the underlying creep mechanisms.« less

Low-Cobalt Powder-Metallurgy Superalloy

NASA Technical Reports Server (NTRS)

Harf, F. H.

1986-01-01

Highly-stressed jet-engine parts made with less cobalt. Udimet 700* (or equivalent) is common nickel-based superalloy used in hot sections of jet engines for many years. This alloy, while normally used in wrought condition, also gas-atomized into prealloyed powder-metallurgy (PM) product. Product can be consolidated by hot isostatically pressing (HIPPM condition) and formed into parts such as turbine disk. Such jet-engine disks "see" both high stresses and temperatures to 1,400 degrees F (760 degrees C).

A viscoplastic study of crack-tip deformation and crack growth in a nickel-based superalloy at elevated temperature

NASA Astrophysics Data System (ADS)

Zhao, L. G.; Tong, J.

Viscoplastic crack-tip deformation behaviour in a nickel-based superalloy at elevated temperature has been studied for both stationary and growing cracks in a compact tension (CT) specimen using the finite element method. The material behaviour was described by a unified viscoplastic constitutive model with non-linear kinematic and isotropic hardening rules, and implemented in the finite element software ABAQUS via a user-defined material subroutine (UMAT). Finite element analyses for stationary cracks showed distinctive strain ratchetting behaviour near the crack tip at selected load ratios, leading to progressive accumulation of tensile strain normal to the crack-growth plane. Results also showed that low frequencies and superimposed hold periods at peak loads significantly enhanced strain accumulation at crack tip. Finite element simulation of crack growth was carried out under a constant Δ K-controlled loading condition, again ratchetting was observed ahead of the crack tip, similar to that for stationary cracks. A crack-growth criterion based on strain accumulation is proposed where a crack is assumed to grow when the accumulated strain ahead of the crack tip reaches a critical value over a characteristic distance. The criterion has been utilized in the prediction of crack-growth rates in a CT specimen at selected loading ranges, frequencies and dwell periods, and the predictions were compared with the experimental results.

Hydrogen Annealing Of Single-Crystal Superalloys

NASA Technical Reports Server (NTRS)

Smialek, James L.; Schaeffer, John C.; Murphy, Wendy

1995-01-01

Annealing at temperature equal to or greater than 2,200 degrees F in atmosphere of hydrogen found to increase ability of single-crystal superalloys to resist oxidation when subsequently exposed to oxidizing atmospheres at temperatures almost as high. Supperalloys in question are principal constituents of hot-stage airfoils (blades) in aircraft and ground-based turbine engines; also used in other high-temperature applications like chemical-processing plants, coal-gasification plants, petrochemical refineries, and boilers. Hydrogen anneal provides resistance to oxidation without decreasing fatigue strength and without need for coating or reactive sulfur-gettering constituents. In comparison with coating, hydrogen annealing costs less. Benefits extend to stainless steels, nickel/chromium, and nickel-base alloys, subject to same scale-adhesion and oxidation-resistance considerations, except that scale is chromia instead of alumina.

The Effect of Stress and Hot Corrosion on Nickel-Base Superalloys

DTIC Science & Technology

1985-03-01

in a degradation of material properties and reduced component life. Allen and Whitlow(6). stated that superalloys in combustion turbine environments...pins are tested in combustion gas streams at elevated temperatures. A hot corrosion environment is usually simulated by burning a sulfur-containing fuel...corrosion attack frequently observed on combustion turbine blades retrieved from service. Figure 1 shows the effect of salt thickness on hot corrosion

A study of reduced chromium content in a nickel-base superalloy via element substitution and rapid solidification processing. Ph.D. ThesisFinal Report

NASA Technical Reports Server (NTRS)

Powers, William O.

1987-01-01

A study of reduced chromium content in a nickel base superalloy via element substitution and rapid solidification processing was performed. The two elements used as partial substitutes for chromium were Si and Zr. The microstructure of conventionally solidified materials was characterized using microscopy techniques. These alloys were rapidly solidified using the chill block melt spinning technique and the rapidly solidified microstructures were characterized using electron microscopy. The spinning technique and the rapidly solidified microstructures was assessed following heat treatments at 1033 and 1272 K. Rapidly solidified material of three alloys was reduced to particulate form and consolidated using hot isostatic pressing (HIP). The consolidated materials were also characterized using microscopy techniques. In order to evaluate the relative strengths of the consolidated alloys, compression tests were performed at room temperature and 1033 K on samples of as-HIPed and HIPed plus solution treated material. Yield strength, porosity, and oxidation resistance characteristics are given and compared.

Effects of Solid Solution Strengthening Elements Mo, Re, Ru, and W on Transition Temperatures in Nickel-Based Superalloys with High γ'-Volume Fraction: Comparison of Experiment and CALPHAD Calculations

NASA Astrophysics Data System (ADS)

Ritter, Nils C.; Sowa, Roman; Schauer, Jan C.; Gruber, Daniel; Goehler, Thomas; Rettig, Ralf; Povoden-Karadeniz, Erwin; Koerner, Carolin; Singer, Robert F.

2018-06-01

We prepared 41 different superalloy compositions by an arc melting, casting, and heat treatment process. Alloy solid solution strengthening elements were added in graded amounts, and we measured the solidus, liquidus, and γ'-solvus temperatures of the samples by DSC. The γ'-phase fraction increased as the W, Mo, and Re contents were increased, and W showed the most pronounced effect. Ru decreased the γ'-phase fraction. Melting temperatures (i.e., solidus and liquidus) were increased by addition of Re, W, and Ru (the effect increased in that order). Addition of Mo decreased the melting temperature. W was effective as a strengthening element because it acted as a solid solution strengthener and increased the fraction of fine γ'-precipitates, thus improving precipitation strengthening. Experimentally determined values were compared with calculated values based on the CALPHAD software tools Thermo-Calc (databases: TTNI8 and TCNI6) and MatCalc (database ME-NI). The ME-NI database, which was specially adapted to the present investigation, showed good agreement. TTNI8 also showed good results. The TCNI6 database is suitable for computational design of complex nickel-based superalloys. However, a large deviation remained between the experiment results and calculations based on this database. It also erroneously predicted γ'-phase separations and failed to describe the Ru-effect on transition temperatures.

Life Prediction of Turbine Blade Nickel Base Superalloy Single Crystals.

DTIC Science & Technology

1986-08-01

mechanical properties between single crystals and the DS version of Mar-M200. Soon it was recognized again through the mechanical property - structure ... property achievements demonstrated by screening and simulated engine tests. 1 Single crystals are the results of extensive investigation on the mechanical ...behavior, (especially fatigue and creep) of, and the structure - property correlations in the equiaxed and directionally solidified (DS) nickel-base

Analysis of thermoelectric properties of high-temperature complex alloys of nickel-base, iron-base and cobalt-base groups

NASA Technical Reports Server (NTRS)

Holanda, R.

1984-01-01

The thermoelectric properties alloys of the nickel-base, iron-base, and cobalt-base groups containing from 1% to 25% 106 chromium were compared and correlated with the following material characteristics: atomic percent of the principle alloy constituent; ratio of concentration of two constituents; alloy physical property (electrical resistivity); alloy phase structure (percent precipitate or percent hardener content); alloy electronic structure (electron concentration). For solid-solution-type alloys the most consistent correlation was obtained with electron concentration, for precipitation-hardenable alloys of the nickel-base superalloy group, the thermoelectric potential correlated with hardener content in the alloy structure. For solid-solution-type alloys, no problems were found with thermoelectric stability to 1000; for precipitation-hardenable alloys, thermoelectric stability was dependent on phase stability. The effects of the compositional range of alloy constituents on temperature measurement uncertainty are discussed.

Maraging superalloys and heat treatment processes

DOEpatents

Korenko, Michael K.; Gelles, David S.; Thomas, Larry E.

1986-01-01

Described herein are nickel-chromium-iron maraging, gamma prime strengthened superalloys containing about 18 to 25 weight percent nickel, about 4 to 8 weight percent chromium, gamma prime forming elements such as aluminum and/or titanium, and a solid solution strengthening element, such as molybdenum. After heat treatment, which includes at least one ausaging treatment and at least one maraging treatment, a microstructure containing gamma prime phase and decomposed Fe-Ni-Cr type martensite is produced.

A crystallographic model for nickel base single crystal alloys

NASA Technical Reports Server (NTRS)

Dame, L. T.; Stouffer, D. C.

1988-01-01

The purpose of this research is to develop a tool for the mechanical analysis of nickel-base single-crystal superalloys, specifically Rene N4, used in gas turbine engine components. This objective is achieved by developing a rate-dependent anisotropic constitutive model and implementing it in a nonlinear three-dimensional finite-element code. The constitutive model is developed from metallurgical concepts utilizing a crystallographic approach. An extension of Schmid's law is combined with the Bodner-Partom equations to model the inelastic tension/compression asymmetry and orientation-dependence in octahedral slip. Schmid's law is used to approximate the inelastic response of the material in cube slip. The constitutive equations model the tensile behavior, creep response and strain-rate sensitivity of the single-crystal superalloys. Methods for deriving the material constants from standard tests are also discussed. The model is implemented in a finite-element code, and the computed and experimental results are compared for several orientations and loading conditions.

A probabilistic-based approach to monitoring tool wear state and assessing its effect on workpiece quality in nickel-based alloys

NASA Astrophysics Data System (ADS)

Akhavan Niaki, Farbod

The objective of this research is first to investigate the applicability and advantage of statistical state estimation methods for predicting tool wear in machining nickel-based superalloys over deterministic methods, and second to study the effects of cutting tool wear on the quality of the part. Nickel-based superalloys are among those classes of materials that are known as hard-to-machine alloys. These materials exhibit a unique combination of maintaining their strength at high temperature and have high resistance to corrosion and creep. These unique characteristics make them an ideal candidate for harsh environments like combustion chambers of gas turbines. However, the same characteristics that make nickel-based alloys suitable for aggressive conditions introduce difficulties when machining them. High strength and low thermal conductivity accelerate the cutting tool wear and increase the possibility of the in-process tool breakage. A blunt tool nominally deteriorates the surface integrity and damages quality of the machined part by inducing high tensile residual stresses, generating micro-cracks, altering the microstructure or leaving a poor roughness profile behind. As a consequence in this case, the expensive superalloy would have to be scrapped. The current dominant solution for industry is to sacrifice the productivity rate by replacing the tool in the early stages of its life or to choose conservative cutting conditions in order to lower the wear rate and preserve workpiece quality. Thus, monitoring the state of the cutting tool and estimating its effects on part quality is a critical task for increasing productivity and profitability in machining superalloys. This work aims to first introduce a probabilistic-based framework for estimating tool wear in milling and turning of superalloys and second to study the detrimental effects of functional state of the cutting tool in terms of wear and wear rate on part quality. In the milling operation, the

Iron rich low cost superalloys. Ph.D. Thesis. Final Report

NASA Technical Reports Server (NTRS)

Wayne, S. F.

1985-01-01

An iron-rich low-cost superalloy was developed. The alloy, when processed by conventional chill casting, has physical and mechanical properties that compare favorably with existing nickel and cobalt based superalloys while containing significantly lower amounts of strategic elements. Studies were also made on the properties of Cr(20)-Mn(10)-C(3.4)-Fe(bal.), a eutectic alloy processed by chill casting and directional solidification which produced an aligned microstructure consisting of M7C3 fibers in a gamma-Fe matrix. Thermal expansion of the M7C3 (M = Fe, Cr, Mn) carbide lattice was measured up to 800 C and found to be highly anisotropic, with the a-axis being the predominant mode of expansion. Repetitive impact sliding wear experiments performed with the Fe rich eutectic alloy showed that the directionally solidified microstructure greatly improved the alloy's wear resistance as compared to the chill cast microstructure and conventional nickel base superalloys. Studies on the molybdenum cementite phase prove that the crystal structure of the xi phase is not orthorhombic. The crystal structure of the xi phase is made up of octahedra building elements consisting of four Mo and two Fe atoms and trigonal prisms consisting of four Fe and two Mo atoms. The voids are occupied by carbon atoms. The previous chemical formula for the molybdenum cementite MoFe2C is now clearly seen to be Mo12Fe22C10.

Microstructure chemistry and mechanical properties of Ni-based superalloy Rene N4 under irradiation at room temperature

DOE PAGES

Sun, C.; Kirk, M.; Li, M.; ...

2015-06-14

Nickel superalloys with cubic L12 structured γ' (Ni 3(Al, Ti)) precipitates exhibit high strength at high temperatures and excellent corrosion resistance when exposed to water. Unlike prior studies on irradiation damage of other Ni-based superalloys, our study on Rene N4 involves much larger γ' precipitates, ~450 nm in size, a size regime where the irradiation-induced disordering and dissolution kinetics and the corresponding mechanical property evolution are unknown. Under heavy ion irradiation at room temperature, the submicron-sized γ' precipitates were fully disordered at ~0.3 dpa and only later partially dissolved after 75 dpa irradiation. Nanoindentation experiments indicate that the mechanical propertiesmore » of the alloy change significantly, with a dramatic decrease in hardness, with irradiation dose. Three contributions to the change in hardness were examined: defect clusters, disordering and dissolution. Moreover, the generation of defect clusters in the matrix and precipitates slightly increased the indentation hardness, while disordering of the submicron-sized γ' precipitates resulted in a dramatic decrease in the total hardness, which decreased further during the early stages of the intermixing between γ' precipitates and matrix (<18 dpa). As a result, controlling the long-range-ordering and chemical intermixing can be used to tailor the mechanical properties of Ni-based superalloys under irradiation.« less

High temperature deformation mechanisms of L12-containing Co-based superalloys

NASA Astrophysics Data System (ADS)

Titus, Michael Shaw

Ni-based superalloys have been used as the structural material of choice for high temperature applications in gas turbine engines since the 1940s, but their operating temperature is becoming limited by their melting temperature (Tm =1300degrees C). Despite decades of research, no viable alternatives to Ni-based superalloys have been discovered and developed. However, in 2006, a ternary gamma' phase was discovered in the Co-Al-W system that enabled a new class of Co-based superalloys to be developed. These new Co-based superalloys possess a gamma-gamma' microstructure that is nearly identical to Ni-based superalloys, which enables these superalloys to achieve extraordinary high temperature mechanical properties. Furthermore, Co-based alloys possess the added benefit of exhibiting a melting temperature of at least 100degrees C higher than commercial Ni-based superalloys. Superalloys used as the structural materials in high pressure turbine blades must withstand large thermomechanical stresses imparted from the rotating disk and hot, corrosive gases present. These stresses induce time-dependent plastic deformation, which is commonly known as creep, and new superalloys must possess adequate creep resistance over a broad range of temperature in order to be used as the structural materials for high pressure turbine blades. For these reasons, this research focuses on quantifying high temperature creep properties of new gamma'-containing Co-based superalloys and identifying the high temperature creep deformation mechanisms. The high temperature creep properties of new Co- and CoNi-based alloys were found to be comparable to Ni-based superalloys with respect to minimum creep rates and creep-rupture lives at 900degrees C up to the solvus temperature of the gamma' phase. Co-based alloys exhibited a propensity for extended superlattice stacking fault formation in the gamma' precipitates resulting from dislocation shearing events. When Ni was added to the Co-based compositions

Numerical simulation of dendrite growth in nickel-based superalloy and validated by in-situ observation using high temperature confocal laser scanning microscopy

NASA Astrophysics Data System (ADS)

Yan, Xuewei; Xu, Qingyan; Liu, Baicheng

2017-12-01

Dendritic structures are the predominant microstructural constituents of nickel-based superalloys, an understanding of the dendrite growth is required in order to obtain the desirable microstructure and improve the performance of castings. For this reason, numerical simulation method and an in-situ observation technology by employing high temperature confocal laser scanning microscopy (HT-CLSM) were used to investigate dendrite growth during solidification process. A combined cellular automaton-finite difference (CA-FD) model allowing for the prediction of dendrite growth of binary alloys was developed. The algorithm of cells capture was modified, and a deterministic cellular automaton (DCA) model was proposed to describe neighborhood tracking. The dendrite and detail morphology, especially hundreds of dendrites distribution at a large scale and three-dimensional (3-D) polycrystalline growth, were successfully simulated based on this model. The dendritic morphologies of samples before and after HT-CLSM were both observed by optical microscope (OM) and scanning electron microscope (SEM). The experimental observations presented a reasonable agreement with the simulation results. It was also found that primary or secondary dendrite arm spacing, and segregation pattern were significantly influenced by dendrite growth. Furthermore, the directional solidification (DS) dendritic evolution behavior and detail morphology were also simulated based on the proposed model, and the simulation results also agree well with experimental results.

Wrought cobalt- base superalloys

NASA Astrophysics Data System (ADS)

Klarstrom, D. L.

1993-08-01

Wrought cobalt-base superalloys are used extensively in gas turbine engines because of their excellent high-temperature creep and fatigue strengths and resistance to hot corrosion attack. In addition, the unique character of the oxide scales that form on some of the alloys provides outstanding resistance to high-temperature sliding wear. This article provides a review of the evolutionary development of wrought cobalt-base alloys in terms of alloy design and physical metallurgy. The topics include solid-so-lution strengthening, carbide precipitation characteristics, and attempts to introduce age hardening. The use of PHACOMP to enhance thermal stability characteristics and the incorporation of rare-earth ele-ments to improve oxidation resistance is also reviewed and discussed. The further development of cobalt-base superalloys has been severely hampered by past political events, which have accentuated the strategic vulnerability of cobalt as a base or as an alloying element. Consequently, alternative alloys have been developed that use little or no cobalt. One such alternative, Haynes® 230TMalloy, is discussed briefly.

Oxidation in oxygen at 900 deg and 1000 deg C of four nickel-base cast superalloys: NASA-TRW VIA, B-1900, alloy 713C, and IN-738

NASA Technical Reports Server (NTRS)

Fryburg, G. C.; Kohl, F. J.; Stearns, C. A.

1977-01-01

The oxidation at 900 and 1,000 C of four nickel-base superalloys in 1 atmosphere of slowly flowing oxygen was investigated. Thermogravimetric rate data were obtained for periods to 100 hours. The morphology and composition of the oxide scales formed after 100 hours were studied by optical microscopy, X-ray diffraction, electron microprobe, scanning electron microscopy, and X-ray photoelectron spectroscopy (ESCA). Alloys B-1900 and VIA were found to be primarily alumina formers, though probably 25 percent of their surface was covered by CR2O3-containing oxides at 900 C. Alloys 713C and IN-738 were primarily chromia formers, though the surface of 713C at 1,000 C was covered with NiO, and the surface of IN-738 at both temperatures was covered with a thin layer of TiO2.

Oxidation corrosion resistant superalloys and coatings

NASA Technical Reports Server (NTRS)

Jackson, Melvin R. (Inventor); Rairden, III, John R. (Inventor)

1978-01-01

An article of manufacture having improved high temperature oxidation and corrosion resistance comprising: (a) a superalloy substrate containing a carbide reinforcing phase, and (b) a coating consisting of chromium, aluminum, carbon, at least one element selected from iron, cobalt or nickel, and optionally an element selected from yttrium or the rare earth elements.

Oxidation corrosion resistant superalloys and coatings

NASA Technical Reports Server (NTRS)

Jackson, Melvin R. (Inventor); Rairden, III, John R. (Inventor)

1980-01-01

An article of manufacture having improved high temperature oxidation and corrosion resistance comprising: (a) a superalloy substrate containing a carbide reinforcing phase, and (b) a coating consisting of chromium, aluminum, carbon, at least one element selected from iron, cobalt or nickel, and optionally an element selected from yttrium or the rare earth elements.

Processing of Advanced Cast Alloys for A-USC Steam Turbine Applications

NASA Astrophysics Data System (ADS)

Jablonski, Paul D.; Hawk, Jeffery A.; Cowen, Christopher J.; Maziasz, Philip J.

2012-02-01

The high-temperature components within conventional supercritical coal-fired power plants are manufactured from ferritic/martensitic steels. To reduce greenhouse-gas emissions, the efficiency of pulverized coal steam power plants must be increased to as high a temperature and pressure as feasible. The proposed steam temperature in the DOE/NETL Advanced Ultra Supercritical power plant is high enough (760°C) that ferritic/martensitic steels will not work for the majority of high-temperature components in the turbine or for pipes and tubes in the boiler due to temperature limitations of this class of materials. Thus, Ni-based superalloys are being considered for many of these components. Off-the-shelf forged nickel alloys have shown good promise at these temperatures, but further improvements can be made through experimentation within the nominal chemistry range as well as through thermomechanical processing and subsequent heat treatment. However, cast nickel-based superalloys, which possess high strength, creep resistance, and weldability, are typically not available, particularly those with good ductility and toughness that are weldable in thick sections. To address those issues related to thick casting for turbine casings, for example, cast analogs of selected wrought nickel-based superalloys such as alloy 263, Haynes 282, and Nimonic 105 have been produced. Alloy design criteria, melt processing experiences, and heat treatment are discussed with respect to the as-processed and heat-treated microstructures and selected mechanical properties. The discussion concludes with the prospects for full-scale development of a thick section casting for a steam turbine valve chest or rotor casing.

Activity coefficients of NiO and CoO in CaO-Al2O3-SiO2 slag and their application to the recycling of Ni-Co-Fe-based end-of-life superalloys via remelting

NASA Astrophysics Data System (ADS)

Lu, Xin; Miki, Takahiro; Nagasaka, Tetsuya

2017-01-01

To design optimal pyrometallurgical processes for nickel and cobalt recycling, and more particularly for the end-of-life process of Ni-Co-Fe-based end-of-life (EoL) superalloys, knowledge of their activity coefficients in slags is essential. In this study, the activity coefficients of NiO and CoO in CaO-Al2O3-SiO2 slag, a candidate slag used for the EoL superalloy remelting process, were measured using gas/slag/metal equilibrium experiments. These activity coefficients were then used to consider the recycling efficiency of nickel and cobalt by remelting EoL superalloys using CaO-Al2O3-SiO2 slag. The activity coefficients of NiO and CoO in CaO-Al2O3-SiO2 slag both show a positive deviation from Raoult's law, with values that vary from 1 to 5 depending on the change in basicity. The activity coefficients of NiO and CoO peak in the slag with a composition near B = (%CaO)/(%SiO2) = 1, where B is the basicity. We observed that controlling the slag composition at approximately B = 1 effectively reduces the cobalt and nickel oxidation losses and promotes the oxidation removal of iron during the remelting process of EoL superalloys.

Oxidation resistant iron and nickel alloys for high temperature use

NASA Technical Reports Server (NTRS)

Hill, V. L.; Misra, S. K.; Wheaton, H. L.

1970-01-01

Iron-base and nickel-base alloys exhibit good oxidation resistance and improved ductility with addition of small amounts of yttrium, tantalum /or hafnium/, and thorium. They can be used in applications above the operating temperatures of the superalloys, if high strength materials are not required.

Microstructural analysis of laser weld fusion zone in Haynes 282 superalloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Osoba, L.O.; Ding, R.G.; Ojo, O.A., E-mail: ojo@cc.umanitoba.ca

Analytical electron microscopy and spectroscopy analyses of the fusion zone (FZ) microstructure in autogenous laser beam welded Haynes 282 (HY 282) superalloy were performed. The micro-segregation patterns observed in the FZ indicate that Co, Cr and Al exhibited a nearly uniform distribution between the dendrite core and interdendritic regions while Ti and Mo were rejected into the interdendritic liquid during the weld solidification. Transmission electron diffraction analysis and energy dispersive X-ray microanalysis revealed the second phase particles formed along the FZ interdendritic region to be Ti-Mo rich MC-type carbide particles. Weld FZ solidification cracking, which is sometimes associated with themore » formation of {gamma}-{gamma}' eutectic in {gamma}' precipitation strengthened nickel-base superalloys, was not observed in the HY 282 superalloy. Modified primary solidification path due to carbon addition in the newly developed superalloy is used to explain preclusion of weld FZ solidification cracking in the material. - Highlights: Black-Right-Pointing-Pointer A newly developed superalloy was welded by CO{sub 2} laser beam joining technique. Black-Right-Pointing-Pointer Electron microscopy characterization of the weld microstructure was performed. Black-Right-Pointing-Pointer Identified interdendritic microconstituents consist of MC-type carbides. Black-Right-Pointing-Pointer Modification of primary solidification path is used to explain cracking resistance.« less

Creep and Fatigue Interaction in the PWA 1484 Single Crystal Nickel-Base Alloy (Preprint)

DTIC Science & Technology

2011-07-01

work by Zhang et al . has shown that during the early part of fatigue cycling dislocations are formed primarily in the γ matrix with the number of...dislocations increasing with the number of applied cycles [11]. Ott and Mughrabi showed that during fatigue of single crystal nickel base superalloys... al . and their research determined that the fatigue behavior of PWA1484 could be well represented by a Walker type fatigue model that also included

Oxidation and thermal fatigue of coated and uncoated NX-188 nickel-base alloy in a high velocity gas stream

NASA Technical Reports Server (NTRS)

Johnson, J. R.; Young, S. G.

1972-01-01

A cast nickel-base superalloy, NX-188, coated and uncoated, was tested in a high-velocity gas stream for resistance to oxidation and thermal fatigue by cycling between room temperature and 980, 1040, and 1090 C. Contrary to the behavior of more conventional nickel-base alloys, uncoated NX-188 exhibited the greatest weight loss at the lowest test temperature. In general, on the basis of weight change and metallographic observations a coating consisting of vapor-deposited Fe-Cr-Al-Y over a chromized substrate exhibited the best overall performance in resistance to oxidation and thermal fatigue.

Oxidation and emittance of superalloys in heat shield applications

NASA Technical Reports Server (NTRS)

Wiedemann, K. E.; Clark, R. K.; Unnam, J.

1986-01-01

Recently developed superalloys that form alumina coatings have a high potential for heat shield applications for advanced aerospace vehicles at temperatures above 1095C. Both INCOLOY alloy MA 956 (of the Inco Alloys International, Inc.), an iron-base oxide-dispersion-strengthened alloy, and CABOT alloy No. 214 (of the Cabot Corporation), an alumina-forming nickel-chromium alloy, have good oxidation resistance and good elevated temperature strength. The oxidation resistance of both alloys has been attributed to the formation of a thin alumina layer (alpha-Al2O3) at the surface. Emittance and oxidation data were obtained for simulated Space Shuttle reentry conditions using a hypersonic arc-heated wind tunnel. The surface oxides and substrate alloys were characterized using X-ray diffraction and scanning and transmission electron microscopy with an energy-dispersive X-ray analysis unit. The mass loss and emittance characteristics of the two alloys are discussed.

Characterization of Phase Chemistry and Partitioning in a Family of High-Strength Nickel-Based Superalloys

NASA Astrophysics Data System (ADS)

Lapington, M. T.; Crudden, D. J.; Reed, R. C.; Moody, M. P.; Bagot, P. A. J.

2018-06-01

A family of novel polycrystalline Ni-based superalloys with varying Ti:Nb ratios has been created using computational alloy design techniques, and subsequently characterized using atom probe tomography and electron microscopy. Phase chemistry, elemental partitioning, and γ' character have been analyzed and compared with thermodynamic predictions created using Thermo-Calc. Phase compositions and γ' volume fraction were found to compare favorably with the thermodynamically predicted values, while predicted partitioning behavior for Ti, Nb, Cr, and Co tended to overestimate γ' preference over the γ matrix, often with opposing trends vs Nb concentration.

High Temperature Deformation Mechanisms in a DLD Nickel Superalloy

PubMed Central

Davies, Sean; Jeffs, Spencer; Lancaster, Robert; Baxter, Gavin

2017-01-01

The realisation of employing Additive Layer Manufacturing (ALM) technologies to produce components in the aerospace industry is significantly increasing. This can be attributed to their ability to offer the near-net shape fabrication of fully dense components with a high potential for geometrical optimisation, all of which contribute to subsequent reductions in material wastage and component weight. However, the influence of this manufacturing route on the properties of aerospace alloys must first be fully understood before being actively applied in-service. Specimens from the nickel superalloy C263 have been manufactured using Powder Bed Direct Laser Deposition (PB-DLD), each with unique post-processing conditions. These variables include two build orientations, vertical and horizontal, and two different heat treatments. The effects of build orientation and post-process heat treatments on the materials’ mechanical properties have been assessed with the Small Punch Tensile (SPT) test technique, a practical test method given the limited availability of PB-DLD consolidated material. SPT testing was also conducted on a cast C263 variant to compare with PB-DLD derivatives. At both room and elevated temperature conditions, differences in mechanical performances arose between each material variant. This was found to be instigated by microstructural variations exposed through microscopic and Energy Dispersive X-ray Spectroscopy (EDS) analysis. SPT results were also compared with available uniaxial tensile data in terms of SPT peak and yield load against uniaxial ultimate tensile and yield strength. PMID:28772817

The Influence of the Coating Deposition Process on the Interdiffusion Behavior Between Nickel-Based Superalloys and MCrAlY Bond Coats

NASA Astrophysics Data System (ADS)

Elsaß, M.; Frommherz, M.; Oechsner, M.

2018-02-01

In this work, interdiffusion between two nickel-based superalloys and two MCrAlY bond coats is investigated. The MCrAlY bond coats were applied using two different spraying processes, high velocity oxygen fuel spraying (HVOF) and low-pressure plasma spraying. Of primary interest is the evolution of Kirkendall porosity, which can form at the interface between substrate and bond coat and depends largely on the chemical compositions of the coating and substrate. Experimental evidence further suggested that the formation of Kirkendall porosity depends on the coating deposition process. Formation of porosity at the interface causes a degradation of the bonding strength between substrate and coating. After coating deposition, the samples were annealed at 1050 °C for up to 2000 h. Microstructural and compositional analyses were performed to determine and evaluate the Kirkendall porosity. The results reveal a strong influence of both the coating deposition process and the chemical compositions. The amount of Kirkendall porosity formed, as well as the location of appearance, is largely influenced by the coating deposition process. In general, samples with bond coats applied by means of HVOF show accelerated element diffusion. It is hypothesized that recrystallization of the substrate material is a main root cause for these observations.

The Effect of Boron and Zirconium on the Structure and Tensile Properties of the Cast Nickel-Based Superalloy ATI 718Plus

NASA Astrophysics Data System (ADS)

Hosseini, Seyed Ali; Abbasi, Seyed Mehdi; Madar, Karim Zangeneh

2018-04-01

The effects of boron and zirconium on cast structure, hardness, and tensile properties of the nickel-based superalloy 718Plus were investigated. For this purpose, five alloys with different contents of boron and zirconium were cast via vacuum induction melting and then purified via vacuum arc remelting. Microstructural analysis by light-optical microscope and scanning electron microscope equipped with energy-dispersive x-ray spectroscopy and phase studies by x-ray diffraction analysis were performed. The results showed that boron and zirconium tend to significantly reduce dendritic arm spacing and increase the amount of Laves, Laves/gamma eutectic, and carbide phases. It was also found that boron led to the formation of B4C and (Cr, Fe, Mo, Ni, Ti)3B2 phases and zirconium led to the formation of intermetallic phases and ZrC carbide. In the presence of boron and zirconium, the hardness and its difference between dendritic branches and inter-dendritic spaces increased by concentrating such phases as Laves in the inter-dendritic spaces. These elements had a negative effect on tensile properties of the alloy, including ductility and strength, mainly because of the increase in the Laves phase. It should be noted that the largest degradation of the tensile properties occurred in the alloys containing the maximum amount of zirconium.

Effects of Cobalt Concentration on the Relative Resistance to Octahedral and Cube Slip in Nickel-Base Superalloys

NASA Technical Reports Server (NTRS)

Bobeck, Gene E.; Miner, R. V.

1988-01-01

Compression yielding tests were performed at 760 C on crystals of the Ni base superalloys Rene 150 and a modified MAR-M247, both having two different Co concentrations. For both alloy bases, increasing Co concentration was shown to decrease the critical resolved shear stress for octahedral slip, but to have little effect on that for cube slip. The results suggest that decreasing complex stacking fault energy in the gamma-prime with increasing Co could account for the observed effects.

Recent Advances in Nickel Catalysis

PubMed Central

Tasker, Sarah Z.; Standley, Eric A.; Jamison, Timothy F.

2015-01-01

Preface The field of nickel catalysis has made tremendous advances in the past decade. There are several key properties of nickel that have allowed for a broad range of innovative reaction development, such as facile oxidative addition and ready access to multiple oxidation states. In recent years, these properties have been increasingly understood and leveraged to perform transformations long considered exceptionally challenging. Herein, we discuss some of the most recent and significant developments in homogeneous nickel catalysis with an emphasis on both synthetic outcome and mechanism. PMID:24828188

Microstructural response to heat affected zone cracking of prewelding heat-treated Inconel 939 superalloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gonzalez, M.A., E-mail: mgonzalez@comimsa.com.mx; Martinez, D.I., E-mail: dorairma@yahoo.com; Perez, A., E-mail: betinperez@hotmail.com

2011-12-15

The microstructural response to cracking in the heat-affected zone (HAZ) of a nickel-based IN 939 superalloy after prewelding heat treatments (PWHT) was investigated. The PWHT specimens showed two different microstructures: 1) spherical ordered {gamma} Prime precipitates (357-442 nm), with blocky MC and discreet M{sub 23}C{sub 6} carbides dispersed within the coarse dendrites and in the interdendritic regions; and 2) ordered {gamma} Prime precipitates in 'ogdoadically' diced cube shapes and coarse MC carbides within the dendrites and in the interdendritic regions. After being tungsten inert gas welded (TIG) applying low heat input, welding speed and using a more ductile filler alloy,more » specimens with microstructures consisting of spherical {gamma} Prime precipitate particles and dispersed discreet MC carbides along the grain boundaries, displayed a considerably improved weldability due to a strong reduction of the intergranular HAZ cracking associated with the liquation microfissuring phenomena. - Highlights: Black-Right-Pointing-Pointer Homogeneous microstructures of {gamma} Prime spheroids and discreet MC carbides of Ni base superalloys through preweld heat treatments. Black-Right-Pointing-Pointer {gamma} Prime spheroids and discreet MC carbides reduce the intergranular HAZ liquation and microfissuring of Nickel base superalloys. Black-Right-Pointing-Pointer Microstructure {gamma} Prime spheroids and discreet blocky type MC carbides, capable to relax the stress generated during weld cooling. Black-Right-Pointing-Pointer Low welding heat input welding speeds and ductile filler alloys reduce the HAZ cracking susceptibility.« less

Technology of High-speed Direct Laser Deposition from Ni-based Superalloys

NASA Astrophysics Data System (ADS)

Klimova-Korsmik, Olga; Turichin, Gleb; Zemlyakov, Evgeniy; Babkin, Konstantin; Petrovsky, Pavel; Travyanov, Andrey

Recently, additive manufacturing is the one of most perspective technologies; it can replace conventional methods of casting and subsequent time-consuming machining. One of the most interesting additive technologies - high-speed direct laser deposition (HSDLD) allows realizing heterophase process during the manufacturing, which there is process takes place with a partial melting of powder. This is particularly important for materials, which are sensitive to strong fluctuations of temperature treatment regimes, like nickel base alloys with high content of gamma prime phase. This alloys are interested for many industrial areas, mostly there are used in engine systems, aircraft and shipbuilding, aeronautics. Heating and cooling rates during the producing process determine structure and affect on its properties. Using HSDLD process it possible to make a products from Ni superalloys with ultrafine microstructure and satisfactory mechanical characteristics without special subsequent heatreatment.

Additive Manufacturing of IN100 Superalloy Through Scanning Laser Epitaxy for Turbine Engine Hot-Section Component Repair: Process Development, Modeling, Microstructural Characterization, and Process Control

NASA Astrophysics Data System (ADS)

Acharya, Ranadip; Das, Suman

2015-09-01

This article describes additive manufacturing (AM) of IN100, a high gamma-prime nickel-based superalloy, through scanning laser epitaxy (SLE), aimed at the creation of thick deposits onto like-chemistry substrates for enabling repair of turbine engine hot-section components. SLE is a metal powder bed-based laser AM technology developed for nickel-base superalloys with equiaxed, directionally solidified, and single-crystal microstructural morphologies. Here, we combine process modeling, statistical design-of-experiments (DoE), and microstructural characterization to demonstrate fully metallurgically bonded, crack-free and dense deposits exceeding 1000 μm of SLE-processed IN100 powder onto IN100 cast substrates produced in a single pass. A combined thermal-fluid flow-solidification model of the SLE process compliments DoE-based process development. A customized quantitative metallography technique analyzes digital cross-sectional micrographs and extracts various microstructural parameters, enabling process model validation and process parameter optimization. Microindentation measurements show an increase in the hardness by 10 pct in the deposit region compared to the cast substrate due to microstructural refinement. The results illustrate one of the very few successes reported for the crack-free deposition of IN100, a notoriously "non-weldable" hot-section alloy, thus establishing the potential of SLE as an AM method suitable for hot-section component repair and for future new-make components in high gamma-prime containing crack-prone nickel-based superalloys.

Laser Engineered Net Shaping of Nickel-Based Superalloy Inconel 718 Powders onto AISI 4140 Alloy Steel Substrates: Interface Bond and Fracture Failure Mechanism

PubMed Central

Kim, Hoyeol; Cong, Weilong; Zhang, Hong-Chao; Liu, Zhichao

2017-01-01

As a prospective candidate material for surface coating and repair applications, nickel-based superalloy Inconel 718 (IN718) was deposited on American Iron and Steel Institute (AISI) 4140 alloy steel substrate by laser engineered net shaping (LENS) to investigate the compatibility between two dissimilar materials with a focus on interface bonding and fracture behavior of the hybrid specimens. The results show that the interface between the two dissimilar materials exhibits good metallurgical bonding. Through the tensile test, all the fractures occurred in the as-deposited IN718 section rather than the interface or the substrate, implying that the as-deposited interlayer bond strength is weaker than the interfacial bond strength. From the fractography using scanning electron microscopy (SEM) and energy disperse X-ray spectrometry (EDS), three major factors affecting the tensile fracture failure of the as-deposited part are (i) metallurgical defects such as incompletely melted powder particles, lack-of-fusion porosity, and micropores; (ii) elemental segregation and Laves phase, and (iii) oxide formation. The fracture failure mechanism is a combination of all these factors which are detrimental to the mechanical properties and structural integrity by causing premature fracture failure of the as-deposited IN718. PMID:28772702

Laser Engineered Net Shaping of Nickel-Based Superalloy Inconel 718 Powders onto AISI 4140 Alloy Steel Substrates: Interface Bond and Fracture Failure Mechanism.

PubMed

Kim, Hoyeol; Cong, Weilong; Zhang, Hong-Chao; Liu, Zhichao

2017-03-25

As a prospective candidate material for surface coating and repair applications, nickel-based superalloy Inconel 718 (IN718) was deposited on American Iron and Steel Institute (AISI) 4140 alloy steel substrate by laser engineered net shaping (LENS) to investigate the compatibility between two dissimilar materials with a focus on interface bonding and fracture behavior of the hybrid specimens. The results show that the interface between the two dissimilar materials exhibits good metallurgical bonding. Through the tensile test, all the fractures occurred in the as-deposited IN718 section rather than the interface or the substrate, implying that the as-deposited interlayer bond strength is weaker than the interfacial bond strength. From the fractography using scanning electron microscopy (SEM) and energy disperse X-ray spectrometry (EDS), three major factors affecting the tensile fracture failure of the as-deposited part are (i) metallurgical defects such as incompletely melted powder particles, lack-of-fusion porosity, and micropores; (ii) elemental segregation and Laves phase, and (iii) oxide formation. The fracture failure mechanism is a combination of all these factors which are detrimental to the mechanical properties and structural integrity by causing premature fracture failure of the as-deposited IN718.

Orientation and temperature dependence of some mechanical properties of the single-crystal nickel-base superalloy Rene N4. II - Low cycle fatigue behavior

NASA Technical Reports Server (NTRS)

Gabb, T. P.; Gayda, J.; Miner, R. V.

1986-01-01

The low cycle fatigue (LCF) properties of a single-crystal nickel-base superalloy Rene N4, have been examined at 760 and 980 C in air. Specimens having crystallographic orientations near the 001, 011, -111, 023, -236, and -145 lines were tested in fully reversed, total-strain-controlled LCF tests at a frequency of 0.1 Hz. At 760 C, this alloy exhibited orientation dependent tension-compression anisotropies of yielding which continued to failure. Also at 760 C, orientations exhibiting predominately single slip exhibited serrated yielding for many cycles. At 980 C, orientation dependencies of yielding behavior were smaller. In spite of the tension-compression anisotropies, cyclic stress range-strain range behavior was not strongly orientation dependent for either test temperature. Fatigue life on a total strain range basis was highly orientation dependent at 760 and 980 C and was related chiefly to elastic modulus, low modulus orientations having longer lives. Stage I crack growth on 111 planes was dominant at 760 C, while Stage II crack growth occurred at 980 C. Crack initiation generally occurred at near-surface micropores, but occasionally at oxidation spikes in the 980 C tests.

Formation of Minor Phases in a Nickel-Based Disk Superalloy

NASA Technical Reports Server (NTRS)

Gabb, T. P.; Garg, A.; Miller, D. R.; Sudbrack, C. K.; Hull, D. R.; Johnson, D.; Rogers, R. B.; Gayda, J.; Semiatin, S. L.

2012-01-01

The minor phases of powder metallurgy disk superalloy LSHR were studied. Samples were consistently heat treated at three different temperatures for long times to approximate equilibrium. Additional heat treatments were also performed for shorter times, to then assess non-equilibrium conditions. Minor phases including MC carbides, M23C6 carbides, M3B2 borides, and sigma were identified. Their transformation temperatures, lattice parameters, compositions, average sizes and total area fractions were determined, and compared to estimates of an existing phase prediction software package. Parameters measured at equilibrium sometimes agreed reasonably well with software model estimates, with potential for further improvements. Results for shorter times representing non-equilibrium indicated significant potential for further extension of the software to such conditions, which are more commonly observed during heat treatments and service at high temperatures for disk applications.

The effect of hydrogen and microstructure on the deformation and fracture behavior of a single crystal nickel-base superalloy. Final Report Ph.D. Thesis

NASA Technical Reports Server (NTRS)

Walston, William S.

1990-01-01

A study was conducted on the effects of internal hydrogen and microstructure on the deformation and fracture of a single crystal nickel-base superalloy. In particular, room temperature plane strain fracture toughness and tensile tests were performed on hydrogen-free and hydrogen charged samples of PWA 1480. The role of microstructure was incorporated by varying the levels of porosity and eutectic gamma/gamma prime through hot isostatic pressing and heat treatment. The room temperature behavior of PWA 1480 was unusual because precipitate shearing was not the primary deformation mechanism at all strains. At strains over 1 percent, dislocations were trapped in the gamma matrix and an attempt was made to relate this behavior to compositional differences between PWA 1480 and other superalloys. Another unique feature of the tensile behavior was cleavage of the eutectic gamma/gamma prime, which is believed to initiate the failure process. Fracture occurred on (111) planes and is likely a result of shear localization along these planes. Elimination of the eutectic gamma/gamma prime greatly improved the tensile ductility, but pososity had no effect on tensile properties. Large quantities of hydrogen (1.74 at. percent) were gas-phase charged into the material, but surprisingly this was not a function of the amount of porosity or eutectic gamma/gamma prime present. Desorption experiments suggest that the vast majority of hydrogen is at reversible lattice trapping sites. This large, uniform concentration of hydrogen dramatically reduced the tensile strain to failure, but only slightly affected the reduction in area. Available hydrogen embrittlement models were examined in light of these results and it was found that the hydrogen enhanced localized plasticity model can explain much of the tensile behavior. K(IC) fracture toughness tests were conducted, but it was necessary to also perform J(IC) tests to provide valid data.

Quantitative characterization and comparison of precipitate and grain shape in Nickel -base superalloys using moment invariants

NASA Astrophysics Data System (ADS)

Callahan, Patrick Gregory

A fundamental objective of materials science and engineering is to understand the structure-property-processing-performance relationship. We need to know the true 3-D microstructure of a material to understand certain geometric properties of a material, and thus fulfill this objective. Focused ion beam (FIB) serial sectioning allows us to find the true 3-D microstructure of Ni-base superalloys. Once the true 3-D microstructure is obtained, an accurate quantitative description and characterization of precipitate and/or grain shapes is needed to understand the microstructure and describe it in an unbiased way. In this thesis, second order moment invariants, the shape quotient Q, a convexity measure relating the volume of an object to the volume of its convex hull, V/Vconv, and Gaussian curvature have been used to compare an experimentally observed polycrystalline IN100 microstructure to three synthetic microstructures. The three synthetic microstructures used different shape classes to produce starting grain shapes. The three shape classes are ellipsoids, superellipsoids, and the shapes generated when truncating a cube with an octahedron. The microstructures are compared using a distance measure, the Hellinger distance. The Hellinger distance is used to compare distributions of shape descriptors for the grains in each microstructure. The synthetic microstructure that has the smallest Hellinger distance, and so best matched the experimentally observed microstructure is the microstructure that used superellipsoids as a starting grain shape. While it has the smallest Hellinger distance, and is approaching realistic grain morphologies, the superellipsoidal microstructure is still not realistic. Second order moment invariants, Q, and V/V conv have also been used to characterize the γ' precipitate shapes from four experimental Ru-containing Ni-base superalloys with differences in alloying additions. The superalloys are designated UM-F9, UM-F18, UM-F19, and UM-F22. The

Development of high temperature nickel-base alloys for jet engine turbine bucket applications

NASA Technical Reports Server (NTRS)

Quigg, R. J.; Scheirer, S. T.

1965-01-01

A program has been initiated to develop a material with superior properties at elevated temperatures for utilization in turbine blade applications. A nickel-base superalloy can provide the necessary high temperature strength by using the maximum capability of the three available strengthening mechanisms - intermetallic gamma prime precipitation (Ni3Al), solid solution strengthening with refractory and precious metals, and stable carbide formations through the addition of strong carbide forming elements. A stress rupture test at 2000 deg F and 15,000 psi was formulated to approximate the desired properties. By adding varying amounts of refractory metals (Mo, W and Ta) it was possible to statistically analyze the effects of each in a basic superalloy composition containing fixed amounts of Co, Cr, C, B, Sr, and Ni at three separate levels of AL and Ta. Metallographic analysis correlated with the mechanical properties of the alloys; those with few strengthening phases were weak and ductile and those with excessive amounts of intermetallic phases present in undesirable morphologies were brittle.

Superalloy Lattice Block Developed for Use in Lightweight, High-Temperature Structures

NASA Technical Reports Server (NTRS)

Hebsur, Mohan G.; Whittenberger, J. Daniel; Krause, David L.

2003-01-01

Successful development of advanced gas turbine engines for aircraft will require lightweight, high-temperature components. Currently titanium-aluminum- (TiAl) based alloys are envisioned for such applications because of their lower density (4 g/cm3) in comparison to superalloys (8.5 g/cm3), which have been utilized for hot turbine engine parts for over 50 years. However, a recently developed concept (lattice block) by JAMCORP, Inc., of Willmington, Massachusetts, would allow lightweight, high-temperature structures to be directly fabricated from superalloys and, thus, take advantage of their well-known, characterized properties. In its simplest state, lattice block is composed of thin ligaments arranged in a three dimensional triangulated trusslike configuration that forms a structurally rigid panel. Because lattice block can be fabricated by casting, correctly sized hardware is produced with little or no machining; thus very low cost manufacturing is possible. Together, the NASA Glenn Research Center and JAMCORP have extended their lattice block methodology for lower melting materials, such as Al alloys, to demonstrate that investment casting of superalloy lattice block is possible. This effort required advances in lattice block pattern design and assembly, higher temperature mold materials and mold fabrication technology, and foundry practice suitable for superalloys (ref. 1). Lattice block panels have been cast from two different Ni-base superalloys: IN 718, which is the most commonly utilized superalloy and retains its strength up to 650 C; and MAR M247, which possesses excellent mechanical properties to at least 1100 C. In addition to the open-cell lattice block geometry, same-sized lattice block panels containing a thin (1-mm-thick) solid face on one side have also been cast from both superalloys. The elevated-temperature mechanical properties of the open cell and face-sheeted superalloy lattice block panels are currently being examined, and the

Fatigue Behavior and Deformation Mechanisms in Inconel 718 Superalloy Investigated

NASA Technical Reports Server (NTRS)

2005-01-01

The nickel-base superalloy Inconel 718 (IN 718) is used as a structural material for a variety of components in the space shuttle main engine (SSME) and accounts for more than half of the total weight of this engine. IN 718 is the bill-of-material for the pressure vessels of nickel-hydrogen batteries for the space station. In the case of the space shuttle main engine, structural components are typically subjected to startup and shutdown load transients and occasional overloads in addition to high-frequency vibratory loads from routine operation. The nickel-hydrogen battery cells are prooftested before service and are subjected to fluctuating pressure loads during operation. In both of these applications, the structural material is subjected to a monotonic load initially, which is subsequently followed by fatigue. To assess the life of these structural components, it is necessary to determine the influence of a prior monotonic load on the subsequent fatigue life of the superalloy. An insight into the underlying deformation and damage mechanisms is also required to properly account for the interaction between the prior monotonic load and the subsequent fatigue loading. An experimental investigation was conducted to establish the effect of prior monotonic straining on the subsequent fatigue behavior of wrought, double-aged, IN 718 at room temperature. First, monotonic strain tests and fully-reversed, strain-controlled fatigue tests were conducted on uniform-gage-section IN 718 specimens. Next, fully reversed fatigue tests were conducted under strain control on specimens that were monotonically strained in tension. Results from this investigation indicated that prior monotonic straining reduced the fatigue resistance of the superalloy particularly at the lowest strain range. Some of the tested specimens were sectioned and examined by transmission electron microscopy to reveal typical microstructures as well as the active deformation and damage mechanisms under each of

High Temperature Brush Seal Tuft Testing of Selected Nickel-Chrome and Cobalt-Chrome Superalloys

NASA Technical Reports Server (NTRS)

Fellenstein, James A.; DellaCorte, Christopher; Moore, Kenneth D.; Boyes, Esther

1997-01-01

The tribology of brush seals is of considerable interest to turbine engine designers because bristle wear continues to limit long term seal performance and life. To provide better materials characterization and foster the development of improved seals, NASA Lewis has developed a brush seal tuft tester. In this test, a 'paintbrush' sample tuft is loaded under constant contact pressure against the outside diameter of a rotating journal. With this configuration, load and friction are directly measured and accurate wear measurements are possible. Previously reported research using this facility showed excellent data repeatability and wear morphology similar to published seal data and dynamic rig tests. This paper is an update of the ongoing research into the tribology of brush seals. The effects of wire materials processing on seal wear and the tribological results for three journal coatings are discussed. Included in the materials processing were two nickel-chrome superalloys each processed to two different yield strengths. The results suggest that seal wear is dependent more on material composition than processing conditions.

NASA Lewis Helps Develop Advanced Saw Blades for the Lumber Industry

NASA Technical Reports Server (NTRS)

1998-01-01

NASA Lewis Research Center's Structures and Material Divisions are centers of excellence in high-temperature alloys for aerospace applications such as advanced aircraft and rocket engines. Lewis' expertise in these fields was enlisted in the development of a new generation of circular sawblades for the lumber industry to use in cutting logs into boards. The U.S. Department of Agriculture's (USDA) Forest Products Laboratory and their supplier had succeeded in developing a thinner sawblade by using a nickel-based alloy, but they needed to reduce excessive warping due to residual stresses. They requested assistance from Lewis' experts, who successfully eliminated the residual stress problem and increased blade strength by over 12 percent. They achieved this by developing an innovative heat treatment based on their knowledge of nickel-based superalloys used in aeropropulsion applications.

Thermodynamic description of multicomponent nickel-base superalloys containing aluminum, chromium, ruthenium and platinum: A computational thermodynamic approach coupled with experiments

NASA Astrophysics Data System (ADS)

Zhu, Jun

Ru and Pt are candidate additional component for improving the high temperature properties of Ni-base superalloys. A thermodynamic description of the Ni-Al-Cr-Ru-Pt system, serving as an essential knowledge base for better alloy design and processing control, was developed in the present study by means of thermodynamic modeling coupled with experimental investigations of phase equilibria. To deal with the order/disorder transition occurring in the Ni-base superalloys, a physical sound model, Cluster/Site Approximation (CSA) was used to describe the fcc phases. The CSA offers computational advantages, without loss of accuracy, over the Cluster Variation Method (CVM) in the calculation of multicomponent phase diagrams. It has been successfully applied to fcc phases in calculating technologically important Ni-Al-Cr phase diagrams. Our effort in this study focused on the two key ternary systems: Ni-Al-Ru and Ni-Al-Pt. The CSA calculated Ni-Al-Ru ternary phase diagrams are in good agreement with the experimental results in the literature and from the current study. A thermodynamic description of quaternary Ni-Al-Cr-Ru was obtained based on the descriptions of the lower order systems and the calculated results agree with experimental data available in literature and in the current study. The Ni-Al-Pt system was thermodynamically modeled based on the limited experimental data available in the literature and obtained from the current study. With the help of the preliminary description, a number of alloy compositions were selected for further investigation. The information obtained was used to improve the current modeling. A thermodynamic description of the Ni-Al-Cr-Pt quaternary was then obtained via extrapolation from its constituent lower order systems. The thermodynamic description for Ni-base superalloy containing Al, Cr, Ru and Pt was obtained via extrapolation. It is believed to be reliable and useful to guide the alloy design and further experimental investigation.

Sodium sulfate-induced corrosion of pure nickel and superalloy Udimet 700 in a high velocity burner rig at 900 C

NASA Technical Reports Server (NTRS)

Misra, A. K.

1987-01-01

Sodium sulfate-induced corrosion of pure nickel and a commercial nickel-base superalloy, Udimet 700 (U-700), were studied at 900 C in a Mach 0.3 burner rig with different Na levels in the combustor. The corrosion rate of Ni was independent of the Na level in the combustor and considerably lower than that measured in laboratory salt spray tests. The lower rates are associated with the deposition of only a small amount of Na2SO4 on the surface of the NiO scale. Corrosion of U-700 was observed to occur in two stages. During the first stage, the corrosion proceeds by reaction of Cr2O3 scale with the Na2SO4 and evaporation of the Na2CrO4 reaction product from the surface of the corroding sample. Cr depletion in the alloy occurs and small sulfide particles are formed in the Cr depletion zone. Extensive sulfidation occurs during the second state of corrosion, and a thick scale forms. The relationship between the corrosion rate of U-700 and the Na level in the combustor gives a good correlation in the range of 0.3 to 1.5 ppm by weight Na. Very low levels of Na in the combustor cause accelerated oxidation of U-700 without producing the typical hot corrosion morphology.

Alloy Design Challenge: Development of Low Density Superalloys for Turbine Blade Applications

NASA Technical Reports Server (NTRS)

MacKay, Rebecca A.; Gabb, Timothy P.; Smialek, James L.; Nathal, Michael V.

2009-01-01

New low density single crystal (LDS) alloys have been developed for turbine blade applications, which have the potential for significant improvements in the thrust to weight ratio over current production alloys. An innovative alloying strategy was identified to achieve high temperature creep resistance, alloy density reductions, microstructural stability, and cyclic oxidation resistance. The approach relies on the use of molybdenum (Mo) as a potent solid solution strengthener for the nickel (Ni)-base superalloy; Mo has a density much closer to Ni than other refractory elements, such as rhenium (Re) or tungsten (W). A host of testing and microstructural examinations was conducted on the superalloy single crystals, including creep rupture testing, microstructural stability, cyclic oxidation, and hot corrosion. The paper will provide an overview of the single crystal properties that were generated in this new superalloy design space. The paper will also demonstrate the feasibility of this innovative approach of low density single crystal superalloy design. It will be shown that the best LDS alloy possesses the best attributes of three generations of single crystal alloys: the low density of first-generation single crystal alloys, the excellent oxidation resistance of second-generation single crystal alloys, and a creep strength which exceeds that of second and third generation alloys.

A Review on Inertia and Linear Friction Welding of Ni-Based Superalloys

NASA Astrophysics Data System (ADS)

Chamanfar, Ahmad; Jahazi, Mohammad; Cormier, Jonathan

2015-04-01

Inertia and linear friction welding are being increasingly used for near-net-shape manufacturing of high-value materials in aerospace and power generation gas turbines because of providing a better quality joint and offering many advantages over conventional fusion welding and mechanical joining techniques. In this paper, the published works up-to-date on inertia and linear friction welding of Ni-based superalloys are reviewed with the objective to make clarifications on discrepancies and uncertainties reported in literature regarding issues related to these two friction welding processes as well as microstructure, texture, and mechanical properties of the Ni-based superalloy weldments. Initially, the chemical composition and microstructure of Ni-based superalloys that contribute to the quality of the joint are reviewed briefly. Then, problems related to fusion welding of these alloys are addressed with due consideration of inertia and linear friction welding as alternative techniques. The fundamentals of inertia and linear friction welding processes are analyzed next with emphasis on the bonding mechanisms and evolution of temperature and strain rate across the weld interface. Microstructural features, texture development, residual stresses, and mechanical properties of similar and dissimilar polycrystalline and single crystal Ni-based superalloy weldments are discussed next. Then, application of inertia and linear friction welding for joining Ni-based superalloys and related advantages over fusion welding, mechanical joining, and machining are explained briefly. Finally, present scientific and technological challenges facing inertia and linear friction welding of Ni-based superalloys including those related to modeling of these processes are addressed.

Embrittlement of nickel-, cobalt-, and iron-base superalloys by exposure to hydrogen

NASA Technical Reports Server (NTRS)

Gray, H. R.

1975-01-01

Five nickel-base alloys (Inconel 718, Udimet 700, Rene 41, Hastelloy X, and TD-NiCr), one cobalt-base alloy (L-605), and an iron-base alloy (A-286) were exposed in hydrogen at 0.1 MN/sq m (15 psi) at several temperatures in the range from 430 to 980 C for as long as 1000 hours. These alloys were embrittled to varying degrees by such exposures in hydrogen. Embrittlement was found to be: (1) sensitive to strain rate, (2) reversible, (3) caused by large concentrations of absorbed hydrogen, and (4) not associated with any detectable microstructural changes in the alloys. These observations are consistent with a mechanism of internal reversible hydrogen embrittlement.

Segregation of impurities at γ' (L12) / γ (fcc) interfaces in a Ni-based superalloy

NASA Astrophysics Data System (ADS)

Tafen, De Nyago; Gao, Michael

2011-03-01

One of the most technologically advanced energy conversion devices is the gas turbine used in aerospace jet engines and gas- fired land-based turbines for electricity generation, fabricated from Ni-based superalloys. However, these materials lack of long- term mechanical and microstructure stability, which is largely due to an excessive coarsening of γ ' that can cause substantial loss of creep resistance and mechanical instability at high temperatures. Theoretical prediction of the creep rate of these important compounds is very imperative, but yet is extremely challenging. Interfacial energy is one of the most important factors that control the coarsening kinetics of these important phases. It indirectly determines the creep resistance of the alloy through the coarsening rate of the strengthening precipitate phase. In this talk, we will present the results of various γ ' / γ interfaces of a Ni-based superalloy obtained using DFT calculations. Then, we will discuss the segregation of impurities at these interfaces. Minor alloying elements in superalloys can alter the interfacial energy between γ and γ ' , and change the strength behavior of the alloy. Alloying elements or impurity species can segregate to interfaces. A favorable segregation would result in enhancing the interfacial cohesion and thus lower the energy.

Retention of Compressive Residual Stresses Introduced by Shot Peening in a Powder Metal Disk Superalloy

NASA Technical Reports Server (NTRS)

Gabb, Timothy P.; Danetti, Andrew; Draper, Susan L.; Locci, Ivan E.; Telesman, Jack

2016-01-01

The fatigue lives of disk superalloys can be increased by shot peening their surfaces, to induce compressive residual stresses near the surface that impede cracking there. As disk application temperatures increase for improved efficiency, the persistence of these beneficial stresses could be impaired, especially with continued fatigue cycling. The objective of this work was to study the retention of residual stresses introduced by shot peening, when subjected to fatigue and high temperatures. Fatigue specimens of powder metallurgy processed nickel-base disk superalloy ME3 were prepared with consistent processing and heat treatment. They were then shot peened using varied conditions. Strain-controlled fatigue cycles were run at room temperature and 704 C, to allow re-assessment of residual stresses.

Discrete statistical model of fatigue crack growth in a Ni-base superalloy, capable of life prediction

NASA Astrophysics Data System (ADS)

Boyd-Lee, Ashley; King, Julia

1992-07-01

A discrete statistical model of fatigue crack growth in a nickel base superalloy Waspaloy, which is quantitative from the start of the short crack regime to failure, is presented. Instantaneous crack growth rate distributions and persistence of arrest distributions are used to compute fatigue lives and worst case scenarios without extrapolation. The basis of the model is non-material specific, it provides an improved method of analyzing crack growth rate data. For Waspaloy, the model shows the importance of good bulk fatigue crack growth resistance to resist early short fatigue crack growth and the importance of maximizing crack arrest both by the presence of a proportion of small grains and by maximizing grain boundary corrugation.

NASA Lewis advanced IPV nickel-hydrogen technology

NASA Technical Reports Server (NTRS)

Smithrick, John J.; Britton, Doris L.

1993-01-01

Individual pressure vessel (IPV) nickel-hydrogen technology was advanced at NASA Lewis and under Lewis contracts. Some of the advancements are as follows: to use 26 percent potassium hydroxide electrolyte to improve cycle life and performance, to modify the state of the art cell design to eliminate identified failure modes and further improve cycle life, and to develop a lightweight nickel electrode to reduce battery mass, hence reduce launch and/or increase satellite payload. A breakthrough in the LEO cycle life of individual pressure vessel nickel-hydrogen battery cells was reported. The cycle life of boiler plate cells containing 26 percent KOH electrolyte was about 40,000 accelerated LEO cycles at 80 percent DOD compared to 3,500 cycles for cells containing 31 percent KOH. Results of the boiler plate cell tests have been validated at NWSC, Crane, Indiana. Forty-eight ampere-hour flight cells containing 26 and 31 percent KOH have undergone real time LEO cycle life testing at an 80 percent DOD, 10 C. The three cells containing 26 percent KOH failed on the average at cycle 19,500. The three cells containing 31 percent KOH failed on the average at cycle 6,400. Validation testing of NASA Lewis 125 Ah advanced design IPV nickel-hydrogen flight cells is also being conducted at NWSC, Crane, Indiana under a NASA Lewis contract. This consists of characterization, storage, and cycle life testing. There was no capacity degradation after 52 days of storage with the cells in the discharged state, on open circuit, 0 C, and a hydrogen pressure of 14.5 psia. The catalyzed wall wick cells have been cycled for over 22,694 cycles with no cell failures in the continuing test. All three of the non-catalyzed wall wick cells failed (cycles 9,588; 13,900; and 20,575). Cycle life test results of the Fibrex nickel electrode has demonstrated the feasibility of an improved nickel electrode giving a higher specific energy nickel-hydrogen cell. A nickel-hydrogen boiler plate cell using an 80

Additional thermal fatigue data on nickel and cobalt-base superalloys

NASA Technical Reports Server (NTRS)

Howes, M. A. H.

1973-01-01

The fluidized bed technique was used to measure the relative thermal fatigue resistance of 21 superalloys: B1900, B1900 DID, IN-100, MAR-M 200, Udimet 700 wrought and cast, NX-188, WAZ-20, TAZ-8A, M22, IN 713C, IN 738, IN 162, MAR-M 509, Rene 80, RBH, NASA VI A, TD-NiCr, MAR-M 302, WI-52, and X-40. IN-100, MAR-M 200, NX-188, WAZ-20 and TAZ-8A were also tested in the directionally solidified form. B1900, B1900 DID, IN-100, MAR-M200, Udimet 700, NX-188, WAZ-20 and TAZ-8A were tested with surface protection. Among the 36 variations of composition, solidification method, and surface protection the cycles to cracking differed by 2 to 3 orders of magnitude. Some alloys suffered serious weight losses and oxidation. Previous fluidized bed thermal fatigue data on some of these alloys were reported in N71-10027. Thermal fatigue data, oxidation, and dimensional changes are reported in N73-30507. Metallographic and hardness data are given in this report.

An Abnormal Increase of Fatigue Life with Dwell Time during Creep-Fatigue Deformation for Directionally Solidified Ni-Based Superalloy DZ445

NASA Astrophysics Data System (ADS)

Ding, Biao; Ren, Weili; Deng, Kang; Li, Haitao; Liang, Yongchun

2018-03-01

The paper investigated the creep-fatigue behavior for directionally solidified nickel-based superalloy DZ445 at 900 °C. It is found that the fatigue life shows an abnormal increase when the dwell time exceeds a critical value during creep-fatigue deformation. The area of hysteresis loop and fractograph explain the phenomenon quite well. The shortest life corresponds to the maximal area of hysteresis loop, i. e. the maximum energy to be consumed during the creep-fatigue cycle. The fractographic observation of failed samples further supports the abnormal behavior of fatigue life.

Fatigue crack growth and low cycle fatigue of two nickel base superalloys

NASA Technical Reports Server (NTRS)

Stoloff, N. S.; Duquette, D. J.; Choe, S. J.; Golwalkar, S.

1983-01-01

The fatigue crack growth and low cycle fatigue behavior of two P/M superalloys, Rene 95 and Astroloy, in the hot isostatically pressed (HIP) condition, was determined. Test variables included frequency, temperature, environment, and hold times at peak tensile loads (or strains). Crack initiation sites were identified in both alloys. Crack growth rates were shown to increase in argon with decreasing frequency or with the imposition of hold times. This behavior was attributed to the effect of oxygen in the argon. Auger analyses were performed on oxide films formed in argon. Low cycle fatigue lives also were degraded by tensile hold, contrary to previous reports in the literature. The role of environment in low cycle fatigue behavior is discussed.

Tensile Properties and Structure of Several Superalloys after Long- Term Exposure to LiF and Vacuum at 1173 K

NASA Astrophysics Data System (ADS)

Whittenberger, J. D.

1995-12-01

The use of the solid- to- liquid phase transformation of LiF to store thermal energy is under consideration for a space- based solar dynamic system. Although advantageous in terms of its energy density, the melting point of this salt (1121K) is beyond the commonly accepted upper- use temperature of 1100 K for chromium- bearing superalloys in vacuum. However, one commercially available nickel- base superalloy (Hastelloy B- 2) is chromium free; unfortunately, because of its high molybdenum content, this alloy can form phases that cause high- temperature embrittlement. To test the suitability of Hastelloy B- 2, it has been exposed to molten LiF, its vapor and vacuum at 1173 K for 2500, 5000, and 10 h. For control, the chromium- containing cobalt- base Haynes alloy 188 and nickel- base Haynes alloy 230 were also exposed to LiF and vacuum at 1173 K for 5000 h. Neither LiF nor vacuum exposures had any significant effect on Hastelloy B- 2 in terms of microstructural surface damage or weight change. Measurement of the post exposure tensile properties of Hastelloy B- 2, nevertheless, revealed low tensile ductility at 1050 K. Such embrittlement and low strength at elevated temperatures appear to preclude the use of Hastelloy B- 2 as a containment material for LiF. Little evidence of significant attack by LiF was seen in either of the chromium- containing superalloys; however, considerable weight loss and near- surface microstructural damage occurred in both alloys exposed to vacuum. Although measurement of the post exposure room-temperature tensile properties of Haynes alloys 188 and 230 revealed no significant loss of strength or ductility, the severe degree of microstructural damage found in unshielded alloys exposed to vacuum indicates that chromium-bearing superalloys might also be unsuitable for prolonged containment of LiF in space above 1100 K. Keywords

Microstructure and Texture Evolution During Hot Pack Rolling of Nickel-Base Superalloys to Thin Sheet and Foil (Preprint)

DTIC Science & Technology

2011-03-01

quenching . The y’ solvus temperature (Ty’) was found to be -1150°C for alloy 5A and -1220°C for alloy 5C based on isothermal heat treatments performed in...an inert argon atmosphere followed by water quenching . Similar to conventional practices for superalloys, supersolvus hot working (at 1225°C) was...approximately five times larger than that shown in Figure 8 to provide a statistically relevant estimate, only 35 pet. of the grains in this sample were within

Effect of tensile mean stress on fatigue behavior of single-crystal and directionally solidified superalloys

NASA Technical Reports Server (NTRS)

Kalluri, Sreeramesh; Mcgaw, Michael A.

1990-01-01

Two nickel base superalloys, single crystal PWA 1480 and directionally solidified MAR-M 246 + Hf, were studied in view of the potential usage of the former and usage of the latter as blade materials for the turbomachinery of the space shuttle main engine. The baseline zero mean stress (ZMS) fatigue life (FL) behavior of these superalloys was established, and then the effect of tensile mean stress (TMS) on their FL behavior was characterized. At room temperature these superalloys have lower ductilities and higher strengths than most polycrystalline engineering alloys. The cycle stress-strain response was thus nominally elastic in most of the fatigue tests. Therefore, a stress range based FL prediction approach was used to characterize both the ZMS and TMS fatigue data. In the past, several researchers have developed methods to account for the detrimental effect of tensile mean stress on the FL for polycrystalline engineering alloys. However, the applicability of these methods to single crystal and directionally solidified superalloys has not been established. In this study, these methods were applied to characterize the TMS fatigue data of single crystal PWA 1480 and directionally solidified MAR-M 246 + Hf and were found to be unsatisfactory. Therefore, a method of accounting for the TMS effect on FL, that is based on a technique proposed by Heidmann and Manson was developed to characterize the TMS fatigue data of these superalloys. Details of this method and its relationship to the conventionally used mean stress methods in FL prediction are discussed.

Effect of tensile mean stress on fatigue behavior of single-crystal and directionally solidified superalloys

NASA Technical Reports Server (NTRS)

Kalluri, Sreeramesh; Mcgaw, Michael A.

1992-01-01

Two nickel base superalloys, single crystal PWA 1480 and directionally solidified MAR-M 246 + Hf, were studied in view of the potential usage of the former and usage of the latter as blade materials for the turbomachinery of the Space Shuttle main engine. The baseline zero mean stress (ZMS) fatigue life (FL) behavior of these superalloys was established, and then the effect of tensile mean stress (TMS) on their FL behavior was characterized. A stress range based FL prediction approach was used to characterize both the ZMS and TMS fatigue data. In the past, several researchers have developed methods to account for the detrimental effect of tensile mean stress on the FL for polycrystalline engineering alloys. These methods were applied to characterize the TMS fatigue data of single crystal PWA 1480 and directionally solidified MAR-M 246 + Hf and were found to be unsatisfactory. Therefore, a method of accounting for the TMS effect on FL, that is based on a technique proposed by Heidmann and Manson was developed to characterize the TMS fatigue data of these superalloys. Details of this method and its relationship to the conventionally used mean stress methods in FL prediction are discussed.

The Effect of Solution Heat Treatment on an Advanced Nickel-Base Disk Alloy

NASA Technical Reports Server (NTRS)

Gayda, J.; Gabb, T. P.; Kantzos, P. T.

2004-01-01

Five heat treat options for an advanced nickel-base disk alloy, LSHR, have been investigated. These included two conventional solution heat treat cycles, subsolvus/oil quench and supersolvus/fan cool, which yield fine grain and coarse grain microstructure disks respectively, as well as three advanced dual microstructure heat treat (DMHT) options. The DMHT options produce disks with a fine grain bore and a coarse grain rim. Based on an overall evaluation of the mechanical property data, it was evident that the three DMHT options achieved a desirable balance of properties in comparison to the conventional solution heat treatments for the LSHR alloy. However, one of the DMHT options, SUB/DMHT, produced the best set of properties, largely based on dwell crack growth data. Further evaluation of the SUB/DMHT option in spin pit experiments on a generic disk shape demonstrated the advantages and reliability of a dual grain structure at the component level.

Constitutive Modeling of Superalloy Single Crystals and Directionally Solidified Materials

NASA Technical Reports Server (NTRS)

Walker, K. P.; Jordan, E. H.

1985-01-01

A unified viscoplastic constitutive relation based on crystallographic slip theory was developed for the deformation analysis of nickel base face centered cubic superalloy single crystals at elevated temperature. The single crystal theory is embedded in a self consistent method to derive a constitutive relation for a directionally solidified material comprised of a polycrystalline aggregate of columnar cylindrical grains. One of the crystallographic axes of the cylindrical crystals points in the columnar direction while the remaining crystallographic axes are oriented at random in the basal plane perpendicular to the columnar direction. These constitutive formulations are coded in FORTRAN for use in nonlinear finite element and boundary element programs.

Effect of Squareness of Initial γ' Precipitates on Creep-Rupture Life of a Ni-Base Single Crystal Superalloy at 760/982 °C

NASA Astrophysics Data System (ADS)

Shi, Zhenbin; Peng, Zhifang; Luo, Yushi; Xie, Hongji; Jin, Haipeng; Zhao, Yunsong; Mei, Qingsong

2018-05-01

An approach to determination of squareness of initial γ' precipitates (S 2D) is proposed to evaluate its effect on creep-rupture life (t r) of nickel-base single crystal (SC) superalloys. It is found that the 760/982 °C rupture life varied with the change in regional S 2D caused by redistribution of W when 1st-step aging temperature changed in full heat treatment on superalloy DD83 investigated. The longest creep-rupture life occurred at the highest value/the lowest difference in S 2D in the interdendritic regions/between the typical dendritic regions in DD83. It is also found that S 2D is a weighted function of the area fraction (F 2D), spacing (h), and size (d) of γ' precipitates and is closely related to t r in a series of SC superalloys. In addition, the variation of S 2D with F 2D (here, thermodynamic mole fraction is approximately expressed by F 2D) through lattice misfit (δ) in the SC superalloys with F 2D ranging from 60 to 75 pct is well correlated. Therefore, to reveal and to better understand these relationships and correlations may help to optimize the phase variables in order to achieve a long rupture life of SC superalloys. In addition, functions to reveal the interrelationships of F 2D, volume fraction (F 3D), S 2D, and cuboidness (S 3D) of initial γ' precipitates are derived considering their shape changes. All of these are hoped to be helpful in practical applications and in understanding the true meaning of the related variables.

Oxidation Resistance and Critical Sulfur Content of Single-Crystal Superalloys

NASA Technical Reports Server (NTRS)

Smialek, James L.

1997-01-01

The high-temperature components of a jet turbine engine are made from nickel-base superalloys. These components must be able to withstand high stresses, fatigue, and corrosive reactions with high-temperature gases. Such oxidation resistance is associated with slow-growing Al2O3 scales that remain adherent to superalloy components after many thermal cycles. Historically, good oxidation resistance has been obtained by coating these components with Ni-Cr-Al-Y coatings, where small additions of yttrium (Y) were necessary for scale adhesion. Subsequently, it was found that the Y aids scale adhesion by preventing sulfur from segregating to the scale metal interface and thus preventing the sulfur from weakening the oxide-metal bonds. Y is a difficult element to incorporate in single-crystal superalloy castings, but it was shown in early work at the NASA Lewis Research Center that good adhesion could be obtained for low-sulfur, uncoated, singlecrystal superalloys, without Y additions. Low sulfur contents for these uncoated superalloys were achieved in the laboratory by a high-temperature hydrogen annealing process. This process allows segregation and surface cleaning of sulfur monolayers in a reducing environment. Another approach is to remove sulfur from the alloy in the melting process. The present study was designed to establish a guideline for the minimum level of desulfurization needed to achieve maximum performance. Coupons of various thicknesses of the superalloy PWA 1480 were hydrogen annealed at various times (8 to 100 hr) and temperatures (1000 to 1300 C), resulting in coupons with sulfur contents ranging from about 0.05 to 5 ppm. Cyclic oxidation tests at 1100 C were then used to assess adhesion and spalling. The weight change of one set of 20-mil (0.5-mm) samples, annealed for 20 hr at 1000, 1100, 1200, and 1300 C, is shown in the following figure. Clearly, the effect of the annealing temperature is quite dramatic in that the higher temperatures produced scales

Crack initiation modeling of a directionally-solidified nickel-base superalloy

NASA Astrophysics Data System (ADS)

Gordon, Ali Page

Combustion gas turbine components designed for application in electric power generation equipment are subject to periodic replacement as a result of cracking, damage, and mechanical property degeneration that render them unsafe for continued operation. In view of the significant costs associated with inspecting, servicing, and replacing damaged components, there has been much interest in developing models that not only predict service life, but also estimate the evolved microstructural state of the material. This thesis explains manifestations of microstructural damage mechanisms that facilitate fatigue crack nucleation in a newly-developed directionally-solidified (DS) Ni-base superalloy components exposed to elevated temperatures and high stresses. In this study, models were developed and validated for damage and life prediction using DS GTD-111 as the subject material. This material, proprietary to General Electric Energy, has a chemical composition and grain structure designed to withstand creep damage occurring in the first and second stage blades of gas-powered turbines. The service conditions in these components, which generally exceed 600°C, facilitate the onset of one or more damage mechanisms related to fatigue, creep, or environment. The study was divided into an empirical phase, which consisted of experimentally simulating service conditions in fatigue specimens, and a modeling phase, which entailed numerically simulating the stress-strain response of the material. Experiments have been carried out to simulate a variety of thermal, mechanical, and environmental operating conditions endured by longitudinally (L) and transversely (T) oriented DS GTD-111. Both in-phase and out-of-phase thermo-mechanical fatigue tests were conducted. In some cases, tests in extreme environments/temperatures were needed to isolate one or at most two of the mechanisms causing damage. Microstructural examinations were carried out via SEM and optical microscopy. A continuum

Development of a Power Metallurgy Superalloy for Use at 1800-2000 F (980-1090 C)

NASA Technical Reports Server (NTRS)

Kortovich, C. S.

1973-01-01

A program was conducted to develop a powder metallurgy nickel-base superalloy for 1800-2000 F (980-1090 C) temperature applications. The feasibility of a unique concept for alloying carbon into a superalloy powder matrix and achieving both grain growth and a discrete particle grain boundary carbide precipitation was demonstrated. The process consisted of blending metastable carbides with a carbon free base alloy and consolidating this blend by hot extrusion. This was followed by heat treatment to grow a desired ASTM No. 2-3 grain size and to solution the metastable carbides to allow precipitation of discrete particle grain boundary carbides during subsequent aging heat treatments. The best alloy developed during this program was hydrogen-atomized, thermal-mechanically processed, modified MAR-M246 base alloy plus VC (0.28 w/o C). Although below those for cast MAR-M246, the mechanical properties exhibited by this alloy represent the best combination offered by conventional powder metallurgy processing to date.

Modeling Long-term Creep Performance for Welded Nickel-base Superalloy Structures for Power Generation Systems

DOE Office of Scientific and Technical Information (OSTI.GOV)

Shen, Chen

2015-01-01

We report here a constitutive model for predicting long-term creep strain evolution in’ strengthened Ni-base superalloys. Dislocation climb-bypassing’, typical in intermediate’ volume fraction (~20%) alloys, is considered as the primary deformation mechanism. Dislocation shearing’ to anti-phase boundary (APB) faults and diffusional creep are also considered for high-stress and high-temperature low-stress conditions, respectively. Additional damage mechanism is taken into account for rapid increase in tertiary creep strain. The model has been applied to Alloy 282, and calibrated in a temperature range of 1375-1450°F, and stress range of 15-45ksi. The model parameters and a MATLAB code are provided. This report is preparedmore » by Monica Soare and Chen Shen at GE Global Research. Technical discussions with Dr. Vito Cedro are greatly appreciated. This work was supported by DOE program DE-FE0005859« less

Evaluation of powder metallurgy superalloy disk materials

NASA Technical Reports Server (NTRS)

Evans, D. J.

1975-01-01

A program was conducted to develop nickel-base superalloy disk material using prealloyed powder metallurgy techniques. The program included fabrication of test specimens and subscale turbine disks from four different prealloyed powders (NASA-TRW-VIA, AF2-1DA, Mar-M-432 and MERL 80). Based on evaluation of these specimens and disks, two alloys (AF2-1DA and Mar-M-432) were selected for scale-up evaluation. Using fabricating experience gained in the subscale turbine disk effort, test specimens and full scale turbine disks were formed from the selected alloys. These specimens and disks were then subjected to a rigorous test program to evaluate their physical properties and determine their suitability for use in advanced performance turbine engines. A major objective of the program was to develop processes which would yield alloy properties that would be repeatable in producing jet engine disks from the same powder metallurgy alloys. The feasibility of manufacturing full scale gas turbine engine disks by thermomechanical processing of pre-alloyed metal powders was demonstrated. AF2-1DA was shown to possess tensile and creep-rupture properties in excess of those of Astroloy, one of the highest temperature capability disk alloys now in production. It was determined that metallographic evaluation after post-HIP elevated temperature exposure should be used to verify the effectiveness of consolidation of hot isostatically pressed billets.

Welding and brazing of nickel and nickel-base alloys

NASA Technical Reports Server (NTRS)

Mortland, J. E.; Evans, R. M.; Monroe, R. E.

1972-01-01

The joining of four types of nickel-base materials is described: (1) high-nickel, nonheat-treatable alloys, (2) solid-solution-hardening nickel-base alloys, (3) precipitation-hardening nickel-base alloys, and (4) dispersion-hardening nickel-base alloys. The high-nickel and solid-solution-hardening alloys are widely used in chemical containers and piping. These materials have excellent resistance to corrosion and oxidation, and retain useful strength at elevated temperatures. The precipitation-hardening alloys have good properties at elevated temperature. They are important in many aerospace applications. Dispersion-hardening nickel also is used for elevated-temperature service.

Effect of Surface Preparation on the 815°C Oxidation of Single-Crystal Nickel-Based Superalloys

NASA Astrophysics Data System (ADS)

Sudbrack, Chantal K.; Beckett, Devon L.; MacKay, Rebecca A.

2015-11-01

A primary application for single-crystal superalloys has been jet engine turbine blades, where operation temperatures reach well above 1000°C. The NASA Glenn Research Center is considering use of single-crystal alloys for future, lower temperature application in the rims of jet engine turbine disks. Mechanical and environmental properties required for potential disk rim operation at 815°C are being examined, including the oxidation and corrosion behavior, where there is little documentation at intermediate temperatures. In this study, single-crystal superalloys, LDS-1101+Hf and CMSX-4+Y, were prepared with different surface finishes and compared after isothermal and cyclic oxidation exposures. Surface finish has a clear effect on oxide formation at 815°C. Machined low-stress ground surfaces after exposure for 440 h produce thin Al2O3 external scales, which is consistent with higher temperature oxidation, whereas polished surfaces with a mirror finish yield much thicker NiO external scales with subscale of Cr2O3-spinel-Al2O3, which may offer less reliable oxidation resistance. Additional experiments separate the roles of cold-work, localized deformation, and the extent of polishing and surface roughness on oxide formation.

Hydrogen environment embrittlement of astroloy and Udimet 700 (nickel-base) and V-57 (iron-base) superalloys

NASA Technical Reports Server (NTRS)

Gray, H. R.; Joyce, J. P.

1975-01-01

The sensitivity to hydrogen environment embrittlement of three superalloys was determined. Astroloy forgings were resistant to embrittlement during smooth tensile, notched tensile, and creep testing in 3.5-MN/sq m hydrogen over the range 23 to 760 C. The notched tensile strength of Udimet 700 bar stock in hydrogen at 23 C was only 50 percent of the baseline value in helium. Forgings of V-57 were not significantly embrittled by hydrogen during smooth tensile testing over the range 23 to 675 C; creep and rupture lives of V-57 were degraded by hydrogen. Postcreep tensile ductility of V-57 was reduced by 40 percent after creep exposure in hydrogen.

Three-dimensional microstructure simulation of Ni-based superalloy investment castings

NASA Astrophysics Data System (ADS)

Pan, Dong; Xu, Qingyan; Liu, Baicheng

2011-05-01

An integrated macro and micro multi-scale model for the three-dimensional microstructure simulation of Ni-based superalloy investment castings was developed, and applied to industrial castings to investigate grain evolution during solidification. A ray tracing method was used to deal with the complex heat radiation transfer. The microstructure evolution was simulated based on the Modified Cellular Automaton method, which was coupled with three-dimensional nested macro and micro grids. Experiments for Ni-based superalloy turbine wheel investment casting were carried out, which showed a good correspondence with the simulated results. It is indicated that the proposed model is able to predict the microstructure of the casting precisely, which provides a tool for the optimizing process.

Advanced nickel-hydrogen spacecraft battery development

NASA Technical Reports Server (NTRS)

Coates, Dwaine K.; Fox, Chris L.; Standlee, D. J.; Grindstaff, B. K.

1994-01-01

Eagle-Picher currently has several advanced nickel-hydrogen (NiH2) cell component and battery designs under development including common pressure vessel (CPV), single pressure vessel (SPV), and dependent pressure vessel (DPV) designs. A CPV NiH2 battery, utilizing low-cost 64 mm (2.5 in.) cell diameter technology, has been designed and built for multiple smallsat programs, including the TUBSAT B spacecraft which is currently scheduled (24 Nov. 93) for launch aboard a Russian Proton rocket. An advanced 90 mm (3.5 in.) NiH2 cell design is currently being manufactured for the Space Station Freedom program. Prototype 254 mm (10 in.) diameter SPV batteries are currently under construction and initial boilerplate testing has shown excellent results. NiH2 cycle life testing is being continued at Eagle-Picher and IPV cells have currently completed more than 89,000 accelerated LEO cycles at 15% DOD, 49,000 real-time LEO cycles at 30 percent DOD, 37,800 cycles under a real-time LEO profile, 30 eclipse seasons in accelerated GEO, and 6 eclipse seasons in real-time GEO testing at 75 percent DOD maximum. Nickel-metal hydride battery development is continuing for both aerospace and electric vehicle applications. Eagle-Picher has also developed an extensive range of battery evaluation, test, and analysis (BETA) measurement and control equipment and software, based on Hewlett-Packard computerized data acquisition/control hardware.

Additive Manufacturing of Single-Crystal Superalloy CMSX-4 Through Scanning Laser Epitaxy: Computational Modeling, Experimental Process Development, and Process Parameter Optimization

NASA Astrophysics Data System (ADS)

Basak, Amrita; Acharya, Ranadip; Das, Suman

2016-08-01

This paper focuses on additive manufacturing (AM) of single-crystal (SX) nickel-based superalloy CMSX-4 through scanning laser epitaxy (SLE). SLE, a powder bed fusion-based AM process was explored for the purpose of producing crack-free, dense deposits of CMSX-4 on top of similar chemistry investment-cast substrates. Optical microscopy and scanning electron microscopy (SEM) investigations revealed the presence of dendritic microstructures that consisted of fine γ' precipitates within the γ matrix in the deposit region. Computational fluid dynamics (CFD)-based process modeling, statistical design of experiments (DoE), and microstructural characterization techniques were combined to produce metallurgically bonded single-crystal deposits of more than 500 μm height in a single pass along the entire length of the substrate. A customized quantitative metallography based image analysis technique was employed for automatic extraction of various deposit quality metrics from the digital cross-sectional micrographs. The processing parameters were varied, and optimal processing windows were identified to obtain good quality deposits. The results reported here represent one of the few successes obtained in producing single-crystal epitaxial deposits through a powder bed fusion-based metal AM process and thus demonstrate the potential of SLE to repair and manufacture single-crystal hot section components of gas turbine systems from nickel-based superalloy powders.

MC Carbide Characterization in High Refractory Content Powder-Processed Ni-Based Superalloys

NASA Astrophysics Data System (ADS)

Antonov, Stoichko; Chen, Wei; Huo, Jiajie; Feng, Qiang; Isheim, Dieter; Seidman, David N.; Sun, Eugene; Tin, Sammy

2018-04-01

Carbide precipitates in Ni-based superalloys are considered to be desirable phases that can contribute to improving high-temperature properties as well as aid in microstructural refinement of the material; however, they can also serve as crack initiation sites during fatigue. To date, most of the knowledge pertaining to carbide formation has originated from assessments of cast and wrought Ni-based superalloys. As powder-processed Ni-based superalloys are becoming increasingly widespread, understanding the different mechanisms by which they form becomes increasingly important. Detailed characterization of MC carbides present in two experimental high Nb-content powder-processed Ni-based superalloys revealed that Hf additions affect the resultant carbide morphologies. This morphology difference was attributed to a higher magnitude of elastic strain energy along the interface associated with Hf being soluble in the MC carbide lattice. The composition of the MC carbides was studied through atom probe tomography and consisted of a complex carbonitride core, which was rich in Nb and with slight Hf segregation, surrounded by an Nb carbide shell. The characterization results of the segregation behavior of Hf in the MC carbides and the subsequent influence on their morphology were compared to density functional theory calculations and found to be in good agreement, suggesting that computational modeling can successfully be used to tailor carbide features.

MC Carbide Characterization in High Refractory Content Powder-Processed Ni-Based Superalloys

NASA Astrophysics Data System (ADS)

Antonov, Stoichko; Chen, Wei; Huo, Jiajie; Feng, Qiang; Isheim, Dieter; Seidman, David N.; Sun, Eugene; Tin, Sammy

2018-06-01

Carbide precipitates in Ni-based superalloys are considered to be desirable phases that can contribute to improving high-temperature properties as well as aid in microstructural refinement of the material; however, they can also serve as crack initiation sites during fatigue. To date, most of the knowledge pertaining to carbide formation has originated from assessments of cast and wrought Ni-based superalloys. As powder-processed Ni-based superalloys are becoming increasingly widespread, understanding the different mechanisms by which they form becomes increasingly important. Detailed characterization of MC carbides present in two experimental high Nb-content powder-processed Ni-based superalloys revealed that Hf additions affect the resultant carbide morphologies. This morphology difference was attributed to a higher magnitude of elastic strain energy along the interface associated with Hf being soluble in the MC carbide lattice. The composition of the MC carbides was studied through atom probe tomography and consisted of a complex carbonitride core, which was rich in Nb and with slight Hf segregation, surrounded by an Nb carbide shell. The characterization results of the segregation behavior of Hf in the MC carbides and the subsequent influence on their morphology were compared to density functional theory calculations and found to be in good agreement, suggesting that computational modeling can successfully be used to tailor carbide features.

The synchronous improvement of strength and plasticity (SISP) in new Ni-Co based disc superalloys by controling stacking fault energy.

PubMed

Xu, H; Zhang, Z J; Zhang, P; Cui, C Y; Jin, T; Zhang, Z F

2017-08-14

It is a great challenge to improve the strength of disc superalloys without great loss of plasticity together since the microstructures benefiting the strength always do not avail the plasticity. Interestingly, this study shows that the trade-off relationship between strength and plasticity can be broken through decreasing stacking fault energy (SFE) in newly developed Ni-Co based disc superalloys. Axial tensile tests in the temperature range of 25 to 725 °C were carried out in these alloys with Co content ranging from 5% to 23% (wt.%). It is found that the ultimate tensile strength (UTS) and uniform elongation (UE) are improved synchronously when microtwinning is activated by decreasing the SFE at 650 and 725 °C. In contrast, only UTS is improved when stacking fault (SF) dominates the plastic deformation at 25 and 400 °C. These results may be helpful for designing advanced disc superalloys with relatively excellent strength and plasticity simultaneously.

Initial Mechanical Testing of Superalloy Lattice Block Structures Conducted

NASA Technical Reports Server (NTRS)

Krause, David L.; Whittenberger, J. Daniel

2002-01-01

The first mechanical tests of superalloy lattice block structures produced promising results for this exciting new lightweight material system. The testing was performed in-house at NASA Glenn Research Center's Structural Benchmark Test Facility, where small subelement-sized compression and beam specimens were loaded to observe elastic and plastic behavior, component strength levels, and fatigue resistance for hundreds of thousands of load cycles. Current lattice block construction produces a flat panel composed of thin ligaments arranged in a three-dimensional triangulated trusslike structure. Investment casting of lattice block panels has been developed and greatly expands opportunities for using this unique architecture in today's high-performance structures. In addition, advances made in NASA's Ultra-Efficient Engine Technology Program have extended the lattice block concept to superalloy materials. After a series of casting iterations, the nickel-based superalloy Inconel 718 (IN 718, Inco Alloys International, Inc., Huntington, WV) was successfully cast into lattice block panels; this combination offers light weight combined with high strength, high stiffness, and elevated-temperature durability. For tests to evaluate casting quality and configuration merit, small structural compression and bend test specimens were machined from the 5- by 12- by 0.5-in. panels. Linear elastic finite element analyses were completed for several specimen layouts to predict material stresses and deflections under proposed test conditions. The structural specimens were then subjected to room-temperature static and cyclic loads in Glenn's Life Prediction Branch's material test machine. Surprisingly, the test results exceeded analytical predictions: plastic strains greater than 5 percent were obtained, and fatigue lives did not depreciate relative to the base material. These assets were due to the formation of plastic hinges and the redundancies inherent in lattice block construction

Rare-earth metals in nickel aluminide-based alloys: III. Structure and properties of multicomponent Ni3Al-based alloys

NASA Astrophysics Data System (ADS)

Bazyleva, O. A.; Povarova, K. B.; Kazanskaya, N. K.; Drozdov, A. A.

2009-04-01

The possibility of increasing the life of heterophase cast light Ni3Al-based superalloys at temperatures higher than 0.8 T m of Ni3Al is studied when their directional structure is additionally stabilized by nanoprecipitates, which form upon additional alloying of these alloys by refractory and active metals, and using special methods for preparing and melting of an alloy charge. The effect of the method of introducing the main components and refractory reaction-active and surface-active alloying elements into Ni3Al-based cast superalloys, which are thermally stable natural composite materials of the eutectic type, on the structure-phase state and the life of these alloys is studied. When these alloys are melted, it is necessary to perform a set of measures to form particles of refractory oxide cores covered with the β-NiAl phase and, then, γ'prim-Ni3Al phase precipitates during solidification. The latter phase forms the outer shell of grain nuclei, which provides high thermal stability and hot strength of an intermetallic compound-based alloy. As a result, a modified structure that is stabilized by the nanoprecipitates of nickel and aluminum lanthanides and the nanoprecipitates of phases containing refractory metals is formed. This structure enhances the life of the alloy at 1000 °C by a factor of 1.8-2.5.

Effects of Microstructural Parameters on Creep of Nickel-Base Superalloy Single Crystals

NASA Technical Reports Server (NTRS)

MacKay, Rebecca A.; Gabb, Timothy P.; Nathal, Michael V.

2013-01-01

Microstructure-sensitive creep models have been developed for Ni-base superalloy single crystals. Creep rupture testing was conducted on fourteen single crystal alloys at two applied stress levels at each of two temperatures, 982 and 1093 C. The variation in creep lives among the different alloys could be explained with regression models containing relatively few microstructural parameters. At 982 C, gamma-gamma prime lattice mismatch, gamma prime volume fraction, and initial gamma prime size were statistically significant in explaining the creep rupture lives. At 1093 C, only lattice mismatch and gamma prime volume fraction were significant. These models could explain from 84 to 94 percent of the variation in creep lives, depending on test condition. Longer creep lives were associated with alloys having more negative lattice mismatch, lower gamma prime volume fractions, and finer gamma prime sizes. The gamma-gamma prime lattice mismatch exhibited the strongest influence of all the microstructural parameters at both temperatures. Although a majority of the alloys in this study were stable with respect to topologically close packed (TCP) phases, it appeared that up to approximately 2 vol% TCP phase did not affect the 1093 C creep lives under applied stresses that produced lives of approximately 200 to 300 h. In contrast, TCP phase contents of approximately 2 vol% were detrimental at lower applied stresses where creep lives were longer. A regression model was also developed for the as-heat treated initial gamma prime size; this model showed that gamma prime solvus temperature, gamma-gamma prime lattice mismatch, and bulk Re content were all statistically significant.

Influence of the Starting Microstructure on the Hot Deformation Behavior of a Low Stacking Fault Energy Ni-based Superalloy

NASA Astrophysics Data System (ADS)

McCarley, Joshua; Alabbad, B.; Tin, S.

2018-03-01

The influence of varying fractions of primary gamma prime precipitates on the hot deformation and annealing behavior of an experimental Nickel-based superalloy containing 24 wt pct. Co was investigated. Billets heat treated at 1110 °C or 1135 °C were subjected to hot compression tests at temperatures ranging from 1020 °C to 1060 °C and strain rates ranging from 0.001 to 0.1/s. The microstructures were characterized using electron back scatter diffraction in the as-deformed condition as well as following a super-solvus anneal heat treatment at 1140 °C for 1 hour. This investigation sought to quantify and understand what effect the volume fraction of primary gamma prime precipitates has on the dynamic recrystallization behavior and resulting length fraction ∑3 twin boundaries in the low stacking fault superalloy following annealing. Although deformation at the lower temperatures and higher strain rates led to dynamic recrystallization for both starting microstructures, comparatively lower recrystallized fractions were observed in the 1135 °C billet microstructures deformed at strain rates of 0.1/s and 0.05/s. Subsequent annealing of the 1135 °C billet microstructures led to a higher proportion of annealing twins when compared to the annealed 1110 °C billet microstructures.

Microstructural evolution in advanced boiler materials for ultra-supercritical coal power plants

NASA Astrophysics Data System (ADS)

Wu, Quanyan

The goal of improving the efficiency of pulverized coal powerplants has been pursued for decades. The need for greater efficiency and reduced environmental impact is pushing utilities to ultra supercritical conditions (USC), i.e. steam temperatures approaching 760°C under a stress of 35 MPa. The long-term creep strength and environmental resistance requirements imposed by these conditions are clearly beyond the capacity of the currently used ferritic steels and other conventional alloys. As part of a large DOE-funded consortium, new and existing materials based on advanced austenitic stainless steels and nickel base superalloys are being evaluated for these very demanding applications. In the present work, the nickel base superalloys of Inconel 617, CCA617, Haynes 230 and Inconel 740, and austenitic alloys Super 304H and HR6W, were evaluated on their microstructural properties over elevated temperature ageing and creep rupture conditions. The materials were aged for different lengths of time at temperatures relevant to USC applications, i.e., in the range from 700 to 800°C. The precipitation behaviors, namely of the gamma', carbides and eta phase in some conditions in nickel base superalloys, carbides in Haynes 230, Cu-rich precipitates in Super 304H and Laves phase particles in HR6W, were studied in detail using scanning electron microscopy (SEM), transmission electron microscopy (TEM) and related analytical techniques. Particular attention has been given on the structure, morphology and compositional distinctiveness of various phases (including gamma, gamma', carbides, secondary phase precipitates, and other types of particles) and their nature, dislocation structures and other types of defects. The results were presented and discussed in light of associated changes in microhardness in the cases of aged samples, and in close reference to mechanical testing (including tensile and creep rupture tests) wherever available. Several mechanical strengthening

X-ray photoelectron spectroscopy study of nickel and nickel-base alloy surface alterations in simulated hot corrosion conditions with emphasis on eventual application to turbine blade corrosion

NASA Technical Reports Server (NTRS)

Mateescu, G. D.; Smith, S. R.

1979-01-01

Research on the high temperature oxidation and Na2SO4 induced hot corrosion of some nickel base superalloys was accomplished by using ESCA to determine the surface composition of the oxidized or corroded samples. Oxidation was carried out at 900 or 1000 C in slowly flowing O2 for samples of B-1900, NASA-TRW VIA, 713C, and IN-738. Oxidation times ranged from 0.5 to 100 hr. Hot corrosion of B-1900 was induced applying a coating of Na2SO4 to peroxidized samples, the heating to 900 C in slowly flowing O2. For oxidized samples, the predominant type of scale formed by each superalloy was determined, and a marked surface enrichment of Ti was found in each case. For corroded samples, the transfer of significant amounts of material from the oxide layer to the surface of the salt layer was observed to occur long before the onset of accelerating weight-gain. Changes in surface composition were observed to coincide with the beginning of accelerating corrosion, the most striking of which was a tenfold decrease in the sulfur to sodium ration and an increase in the Cr(VI) ratio.

Validation test of 125 Ah advanced design IPV nickel-hydrogen flight cells

NASA Technical Reports Server (NTRS)

Smithrick, John J.; Hall, Stephen W.

1993-01-01

An update of validation test results confirming the advanced design nickel-hydrogen cell is presented. An advanced 125 Ah individual pressure vessel (IPV) nickel-hydrogen cell was designed. The primary function of the advanced cell is to store and deliver energy for long-term, Low-Earth-Orbit (LEO) spacecraft missions. The new features of this design, which are not incorporated in state-of-the-art design cells, are: (1) use of 26 percent rather than 31 percent potassium hydroxide (KOH) electrolyte; (2) use of a patented catalyzed wall wick; (3) use of serrated-edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while still maintaining physical contact with the wall wick for electrolyte management; and (4) use of a floating rather than a fixed stack (state-of-the-art) to accommodate nickel electrode expansion due to charge/discharge cycling. The significant improvements resulting from these innovations are extended cycle life; enhanced thermal, electrolyte, and oxygen management; and accommodation of nickel electrode expansion. Six 125 Ah flight cells based on this design were fabricated by Eagle-Picher. Three of the cells contain all of the advanced features (test cells) and three are the same as the test cells except they do not have catalyst on the wall wick (control cells). All six cells are in the process of being evaluated in a LEO cycle life test at the Naval Weapons Support Center, Crane, IN, under a NASA Lewis Research Center contract. The catalyzed wall wick cells have been cycled for over 19000 cycles with no cell failures in the continuing test. Two of the noncatalyzed wall wick cells failed (cycles 9588 and 13,900).

Compatibility of Niobium Alloys and Superalloys in a Flowing He-Xe Power Conversion System

NASA Technical Reports Server (NTRS)

Bowman, Cheryl L.; Ritzert, Frank J.; Smialek, James L.; Jaster, Mark L.; rker, Samuel P.

2004-01-01

Proposed concepts for an ambitious mission to explore Jupiter's three icy moons place significant demands on the various spacecraft systems. There are many challenges related to the high output power conversion systems being considered, and one example is the need to ensure system compatibility at all levels. The utilization of appropriate materials for component structures is important to ensuring long mission life. Refractory metal alloys have attractive high-temperature properties in inert environments, but these alloys are sometimes susceptible to contamination. Potential material compatibility issues exist between refractory metal candidates and more conventional alloys. Nb-1Zr has long been considered one of the most well characterized refractory alloys that is well suited for elevated-temperature use and liquid-metal compatibility. However, previous studies have suggested that niobium alloys can not co-exist in a closed system with traditional stainless steels or superalloys due to transport of contaminants. The relevance of this information to a proposed power conversion system is discussed. Also, experiments and fundamental calculations are being performed to determine contamination transport from candidate superalloys to Nb-1Zr in a closed system with an inert carrier gas. Potential protective schemes are explored to ensure system level compatibility between the refractory alloy Nb-1Zr and a nickel-based superalloy.

Characterization of the Hot Deformation Behavior of a Newly Developed Nickel-Based Superalloy

NASA Astrophysics Data System (ADS)

Shi, Zhaoxia; Yan, Xiaofeng; Duan, Chunhua; Tang, Cunjiang; Pu, Enxiang

2018-03-01

To clarify the microstructural evolution and hot workability of GH4282 during hot forming processes, the hot deformation behavior of this superalloy was investigated by isothermal compression tests in the temperature interval of 950-1210 °C and the strain rate range of 0.01-10 s-1 with a true strain of 0.7. The results show that the flow stresses decrease with an increase in the deformation temperature and a decrease in the strain rate. The characteristic of dynamic recrystallization is revealed by the flow curves. The variation rule of the flow stress can be well described by the hyperbolic sine type equation, and the thermal deformation activation energy is determined to be 498.118 kJ/mol. The optimum hot working parameters are 1100-1180 °C and 0.01-0.1 s-1, under which the fine and uniform microstructure can be obtained.

Porosity Evolution in a Creeping Single Crystal (Preprint)

DTIC Science & Technology

2012-08-01

1] indicated that the growth of initially present processing induced voids in a nickel based single crystal superalloy played a significant role in...processing induced voids in a nickel based single crystal superalloy played a significant role in limiting creep life. Also, creep tests on single...experimental observations of creep deformation and failure of a nickel based single crystal superalloy, [1, 2]. Metallographic observations have shown that Ni

Development of an experimental setup for testing the properties of γ/γ' superalloys

NASA Astrophysics Data System (ADS)

Christophe, Siret; Bernard, Viguier; Claude, Salabura Jean; Eric, Andrieu; Sandrine, Lesterlin

2010-07-01

Certification tests on turboshaft engines for helicopters can expose components as high pressure turbine blades to very high temperature during short time periods. To simulate these complex temperature and mechanical stress loadings and to study dimensional and microstructural stability under severe testing conditions, an experimental set-up has been recently developed. In this paper, we first present this new device and describe its performances. Then, the device is used to study the effect of heating procedure on creep results at 1200°C and rafting during primary creep on the single crystal nickel-based superalloy MC2.

Fatigue Resistance of the Grain Size Transition Zone in a Dual Microstructure Superalloy Disk

NASA Technical Reports Server (NTRS)

Gabb, T. P.; Kantzos, P. T.; Telesman, J.; Gayda, J.; Sudbrack, C. K.; Palsa, B. S.

2010-01-01

Mechanical property requirements vary with location in nickel-based superalloy disks. To maximize the associated mechanical properties, heat treatment methods have been developed for producing tailored microstructures. In this study, a specialized heat treatment method was applied to produce varying grain microstructures from the bore to the rim portions of a powder metallurgy processed nickel-based superalloy disk. The bore of the contoured disk consisted of fine grains to maximize strength and fatigue resistance at lower temperatures. The rim microstructure of the disk consisted of coarse grains for maximum resistance to creep and dwell crack growth at high temperatures up to 704 C. However, the fatigue resistance of the grain size transition zone was unclear, and needed to be evaluated. This zone was located as a band in the disk web between the bore and rim. Specimens were extracted parallel and transverse to the transition zone, and multiple fatigue tests were performed at 427 and 704 C. Mean fatigue lives were lower at 427 C than for 704 C. Specimen failures often initiated at relatively large grains, which failed on crystallographic facets. Grain size distributions were characterized in the specimens, and related to the grains initiating failures as well as location within the transition zone. Fatigue life decreased with increasing maximum grain size. Correspondingly, mean fatigue resistance of the transition zone was slightly higher than that of the rim, but lower than that of the bore. The scatter in limited tests of replicates was comparable for all transition zone locations examined.

Eutectic Formation During Solidification of Ni-Based Single-Crystal Superalloys with Additional Carbon

NASA Astrophysics Data System (ADS)

Wang, Fu; Ma, Dexin; Bührig-Polaczek, Andreas

2017-11-01

γ/ γ' eutectics' nucleation behavior during the solidification of a single-crystal superalloy with additional carbon was investigated by using directional solidification quenching method. The results show that the nucleation of the γ/ γ' eutectics can directly occur on the existing γ dendrites, directly in the remaining liquid, or on the primary MC-type carbides. The γ/γ' eutectics formed through the latter two mechanisms have different crystal orientations than that of the γ matrix. This suggests that the conventional Ni-based single-crystal superalloy castings with additional carbon only guarantee the monocrystallinity of the γ matrix and some γ/ γ' eutectics and, in addition to the carbides, there are other misoriented polycrystalline microstructures existing in macroscopically considered "single-crystal" superalloy castings.

Fracture of single crystals of the nickel-base superalloy PWA 1480E in helium at 22 C

NASA Technical Reports Server (NTRS)

Chen, P. S.; Wilcox, R. C.

1991-01-01

The fracture behavior and deformation of He-charged (at 22 C) single crystals of PWA 1480E Ni-base superalloy were investigated using SEM and TEM techniques to observe the behavior of tensile fractures in notched single crystals with seven different crystal growth orientations: 100-line, 110-line, 111-line, 013-line, 112-line, 123-line, and 223-line. To identify the cleavage plane orientation, a stereoscopic technique, combined with the use of planar gamma-prime morphologies, was applied. It was found that gamma-prime particles were orderly and closely aligned with edges along the 100-line, 010-line, and 001-line-oriented directions of the gamma matrix. Different crystal growth orientations were found not to affect the morphology of gamma-prime particles. The accumulation of dislocations around gamma/gamma-prime interfaces formed strong barriers to subsequent dislocation movement and was the primary strengthening mechanism at room temperature.

Nickel: makes stainless steel strong

USGS Publications Warehouse

Boland, Maeve A.

2012-01-01

Nickel is a silvery-white metal that is used mainly to make stainless steel and other alloys stronger and better able to withstand extreme temperatures and corrosive environments. Nickel was first identified as a unique element in 1751 by Baron Axel Fredrik Cronstedt, a Swedish mineralogist and chemist. He originally called the element kupfernickel because it was found in rock that looked like copper (kupfer) ore and because miners thought that "bad spirits" (nickel) in the rock were making it difficult for them to extract copper from it. Approximately 80 percent of the primary (not recycled) nickel consumed in the United States in 2011 was used in alloys, such as stainless steel and superalloys. Because nickel increases an alloy's resistance to corrosion and its ability to withstand extreme temperatures, equipment and parts made of nickel-bearing alloys are often used in harsh environments, such as those in chemical plants, petroleum refineries, jet engines, power generation facilities, and offshore installations. Medical equipment, cookware, and cutlery are often made of stainless steel because it is easy to clean and sterilize. All U.S. circulating coins except the penny are made of alloys that contain nickel. Nickel alloys are increasingly being used in making rechargeable batteries for portable computers, power tools, and hybrid and electric vehicles. Nickel is also plated onto such items as bathroom fixtures to reduce corrosion and provide an attractive finish.

Peculiar features of boron distribution in high temperature fracture area of rapidly quenched heat-resistant nickel alloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Shulga, A. V., E-mail: avshulga@mephi.ru

This article comprises the results of comprehensive study of the structure and distribution in the high temperature fracture area of rapidly quenched heat-resistant superalloy of grade EP741NP after tensile tests. The structure and boron distribution in the fracture area are studied in detail by means of direct track autoradiography in combination with metallography of macro- and microstructure. A rather extensive region of microcracks generation and intensive boron redistribution is detected in the high temperature fracture area of rapidly quenched nickel superalloy of grade EP741NP. A significant decrease in boron content in the fracture area and formation of elliptically arranged boridemore » precipitates are revealed. The mechanism of intense boron migration and stability violation of the structural and phase state in the fracture area of rapidly quenched heat-resistant nickel superalloy of grade EP741NP is proposed on the basis of accounting for deformation occurring in the fracture area and analysis of the stressed state near a crack.« less

Advanced designs for IPV nickel-hydrogen cells

NASA Technical Reports Server (NTRS)

Smithrick, J. J.; Manzo, M. A.; Gonzalez-Sanabria, O. D.

1984-01-01

Advanced designs for individual pressure vessel nickel-hydrogen cells have been concieved which should improve the cycle life at deep depths-of-discharge. Features of the designs which are new and not incorporated in either of the contemporary cells (Air Force/Hughes, Comsat) are: (1) use of alternate methods of oxygen recombination, (2) use of serrated edge separators to facilitate movement of gas within the cell while still maintaining required physical contact with the wall wick, and (3) use of an expandable stack to accommodate some of the nickel electrode expansion. The designs also consider electrolyte volume requirements over the life of the cells, and are fully compatible with the Air Force/Hughes design.

Validation test of advanced technology for IPV nickel-hydrogen flight cells: Update

NASA Technical Reports Server (NTRS)

Smithrick, John J.; Hall, Stephen W.

1992-01-01

Individual pressure vessel (IPV) nickel-hydrogen technology was advanced at NASA Lewis and under Lewis contracts with the intention of improving cycle life and performance. One advancement was to use 26 percent potassium hydroxide (KOH) electrolyte to improve cycle life. Another advancement was to modify the state-of-the-art cell design to eliminate identified failure modes. The modified design is referred to as the advanced design. A breakthrough in the low-earth-orbit (LEO) cycle life of IPV nickel-hydrogen cells has been previously reported. The cycle life of boiler plate cells containing 26 percent KOH electrolyte was about 40,000 LEO cycles compared to 3,500 cycles for cells containing 31 percent KOH. The boiler plate test results are in the process of being validated using flight hardware and real time LEO testing at the Naval Weapons Support Center (NWSC), Crane, Indiana under a NASA Lewis Contract. An advanced 125 Ah IPV nickel-hydrogen cell was designed. The primary function of the advanced cell is to store and deliver energy for long-term, LEO spacecraft missions. The new features of this design are: (1) use of 26 percent rather than 31 percent KOH electrolyte; (2) use of a patented catalyzed wall wick; (3) use of serrated-edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while still maintaining physical contact with the wall wick for electrolyte management; and (4) use of a floating rather than a fixed stack (state-of-the-art) to accommodate nickel electrode expansion due to charge/discharge cycling. The significant improvements resulting from these innovations are: extended cycle life; enhanced thermal, electrolyte, and oxygen management; and accommodation of nickel electrode expansion. The advanced cell design is in the process of being validated using real time LEO cycle life testing of NWSC, Crane, Indiana. An update of validation test results confirming this technology is presented.

Measurement of gamma' precipitates in a nickel-based superalloy using energy-filtered transmission electron microscopy coupled with automated segmenting techniques.

PubMed

Tiley, J S; Viswanathan, G B; Shiveley, A; Tschopp, M; Srinivasan, R; Banerjee, R; Fraser, H L

2010-08-01

Precipitates of the ordered L1(2) gamma' phase (dispersed in the face-centered cubic or FCC gamma matrix) were imaged in Rene 88 DT, a commercial multicomponent Ni-based superalloy, using energy-filtered transmission electron microscopy (EFTEM). Imaging was performed using the Cr, Co, Ni, Ti and Al elemental L-absorption edges in the energy loss spectrum. Manual and automated segmentation procedures were utilized for identification of precipitate boundaries and measurement of precipitate sizes. The automated region growing technique for precipitate identification in images was determined to measure accurately precipitate diameters. In addition, the region growing technique provided a repeatable method for optimizing segmentation techniques for varying EFTEM conditions. (c) 2010 Elsevier Ltd. All rights reserved.

Machinability of nickel based alloys using electrical discharge machining process

NASA Astrophysics Data System (ADS)

Khan, M. Adam; Gokul, A. K.; Bharani Dharan, M. P.; Jeevakarthikeyan, R. V. S.; Uthayakumar, M.; Thirumalai Kumaran, S.; Duraiselvam, M.

2018-04-01

The high temperature materials such as nickel based alloys and austenitic steel are frequently used for manufacturing critical aero engine turbine components. Literature on conventional and unconventional machining of steel materials is abundant over the past three decades. However the machining studies on superalloy is still a challenging task due to its inherent property and quality. Thus this material is difficult to be cut in conventional processes. Study on unconventional machining process for nickel alloys is focused in this proposed research. Inconel718 and Monel 400 are the two different candidate materials used for electrical discharge machining (EDM) process. Investigation is to prepare a blind hole using copper electrode of 6mm diameter. Electrical parameters are varied to produce plasma spark for diffusion process and machining time is made constant to calculate the experimental results of both the material. Influence of process parameters on tool wear mechanism and material removal are considered from the proposed experimental design. While machining the tool has prone to discharge more materials due to production of high energy plasma spark and eddy current effect. The surface morphology of the machined surface were observed with high resolution FE SEM. Fused electrode found to be a spherical structure over the machined surface as clumps. Surface roughness were also measured with surface profile using profilometer. It is confirmed that there is no deviation and precise roundness of drilling is maintained.

Gas metal arc welding in refurbishment of cobalt base superalloys

NASA Astrophysics Data System (ADS)

Shahriary, M. S.; Miladi Gorji, Y.; Kolagar, A. M.

2017-01-01

Refurbishments of superalloys which are used in manufacturing gas turbine hot components usually consists of removing cracks and other defects by blending and then repair welding in order to reconstruct damaged area. In this study, the effects of welding parameters on repair of FSX-414 superalloy, as the most applicable cobalt base superalloy in order to manufacture gas turbine nozzles, by use of Gas Metal Arc Welding (GMAW) technic were investigated. Results then were compared by Gas Tungsten Arc Welding (GTAW). Metallographic and SEM studies of the microstructure of the weld and HAZ showed that there are no noticeable defects in the microstructure by use of GMAW. Also, chemical analysis and morphologies of carbide in both methods are similar. Hardness profile of the GM AW structure then also compared with GTAW and no noticeable difference was observed between the profiles. Also, proper tensile properties, compared with GTAW, can be achieved by use of optimum parameters that can be obtained by examining the current and welding speed. Tensile properties of optimized condition of the GMAW then were compared with GTAW. It was seen that the room and high temperature tensile properties of the GMAW structure is very similar and results confirmed that changing the technic did not have any significant influence on the properties.

A synchrotron study of microstructure gradient in laser additively formed epitaxial Ni-based superalloy

DOE PAGES

Xue, Jiawei; Zhang, Anfeng; Li, Yao; ...

2015-10-08

Laser additive forming is considered to be one of the promising techniques to repair single crystal Ni-based superalloy parts to extend their life and reduce the cost. Preservation of the single crystalline nature and prevention of thermal mechanical failure are two of the most essential issues for the application of this technique. Here we employ synchrotron X-ray microdiffraction to evaluate the quality in terms of crystal orientation and defect distribution of a Ni-based superalloy DZ125L directly formed by a laser additive process rooted from a single crystalline substrate of the same material. We show that a disorientation gradient caused bymore » a high density of geometrically necessary dislocations and resultant subgrains exists in the interfacial region between the epitaxial and stray grains. This creates a potential relationship of stray grain formation and defect accumulation. In conclusion, the observation offers new directions on the study of performance control and reliability of the laser additive manufactured superalloys.« less

A synchrotron study of microstructure gradient in laser additively formed epitaxial Ni-based superalloy.

PubMed

Xue, Jiawei; Zhang, Anfeng; Li, Yao; Qian, Dan; Wan, Jingchun; Qi, Baolu; Tamura, Nobumichi; Song, Zhongxiao; Chen, Kai

2015-10-08

Laser additive forming is considered to be one of the promising techniques to repair single crystal Ni-based superalloy parts to extend their life and reduce the cost. Preservation of the single crystalline nature and prevention of thermal mechanical failure are two of the most essential issues for the application of this technique. Here we employ synchrotron X-ray microdiffraction to evaluate the quality in terms of crystal orientation and defect distribution of a Ni-based superalloy DZ125L directly formed by a laser additive process rooted from a single crystalline substrate of the same material. We show that a disorientation gradient caused by a high density of geometrically necessary dislocations and resultant subgrains exists in the interfacial region between the epitaxial and stray grains. This creates a potential relationship of stray grain formation and defect accumulation. The observation offers new directions on the study of performance control and reliability of the laser additive manufactured superalloys.

A synchrotron study of microstructure gradient in laser additively formed epitaxial Ni-based superalloy

PubMed Central

Xue, Jiawei; Zhang, Anfeng; Li, Yao; Qian, Dan; Wan, Jingchun; Qi, Baolu; Tamura, Nobumichi; Song, Zhongxiao; Chen, Kai

2015-01-01

Laser additive forming is considered to be one of the promising techniques to repair single crystal Ni-based superalloy parts to extend their life and reduce the cost. Preservation of the single crystalline nature and prevention of thermal mechanical failure are two of the most essential issues for the application of this technique. Here we employ synchrotron X-ray microdiffraction to evaluate the quality in terms of crystal orientation and defect distribution of a Ni-based superalloy DZ125L directly formed by a laser additive process rooted from a single crystalline substrate of the same material. We show that a disorientation gradient caused by a high density of geometrically necessary dislocations and resultant subgrains exists in the interfacial region between the epitaxial and stray grains. This creates a potential relationship of stray grain formation and defect accumulation. The observation offers new directions on the study of performance control and reliability of the laser additive manufactured superalloys. PMID:26446425

Hydrogen-Resistant Fe/Ni/Cr-Base Superalloy

NASA Technical Reports Server (NTRS)

Bhat, Biliyar N.; Chen, Po-Shou; Panda, Binayak

1994-01-01

Strong Fe/Ni/Cr-base hydrogen- and corrosion-resistant alloy developed. Superalloy exhibits high strength and exceptional resistance to embrittlement by hydrogen. Contains two-phase microstructure consisting of conductivity precipitated phase in conductivity matrix phase. Produced in wrought, weldable form and as castings, alloy maintains high ductility and strength in air and hydrogen. Strength exceeds previously known Fe/Cr/Ni hydrogen-, oxidation-, and corrosion-resistant alloys. Provides higher strength-to-weight ratios for lower weight in applications as storage vessels and pipes that must contain hydrogen.

Role of molybdenum in the Na sub 2SO sub 4 induced corrosion of superalloys at high temperatures

NASA Technical Reports Server (NTRS)

Misra, A. K.

1986-01-01

Sodium sulfate induced corrosion of a molybdenum containing nickel-base superalloy, Udimet 700, was studied in laboratory furnace tests and in a high velocity (Mach 0.3) burner rig. The effect of SO2 content in the atmosphere on the corrosion behavior in the laboratory furnace tests was determined. Catastrophic corrosion occurs only when the melt contains MoO3 in addition to Na2SO4 and Na2MoO4. The conditions under which catastrophic corrosion occurs are identified and a mechanism is described to explain the catastrophic corrosion.

Advanced nickel base alloys for high strength, corrosion applications

DOEpatents

Flinn, John E.

1998-01-01

Improved nickel-base alloys of enhanced strength and corrosion resistance, produced by atomization of an alloy melt under an inert gas atmosphere and of composition 0-20Fe, 10-30Cr, 2-12Mo, 6 max. Nb, 0.05-3 V, 0.08 max. Mn, 0.5 max. Si, less than 0.01 each of Al and Ti, less than 0.05 each of P and S, 0.01-0.08C, less than 0.2N, 0.1 max. 0, bal. Ni.

Validation test of advanced technology for IPV nickel-hydrogen flight cells - Update

NASA Technical Reports Server (NTRS)

Smithrick, John J.; Hall, Stephen W.

1992-01-01

Individual pressure vessel (IPV) nickel-hydrogen technology was advanced at NASA Lewis and under Lewis contracts with the intention of improving cycle life and performance. One advancement was to use 26 percent potassium hydroxide (KOH) electrolyte to improve cycle life. Another advancement was to modify the state-of-the-art cell design to eliminate identified failure modes. The modified design is referred to as the advanced design. A breakthrough in the LEO cycle life of IPV nickel-hydrogen cells has been previously reported. The cycle life of boiler plate cells containing 26 percent KOH electrolyte was about 40,000 LEO cycles compared to 3,500 cycles for cells containing 31 percent KOH. The boiler plate test results are in the process of being validated using flight hardware and real time LEO testing. The primary function of the advanced cell is to store and deliver energy for long-term, LEO spacecraft missions. The new features of this design are: (1) use of 26 percent rather than 31 percent KOH electrolyte; (2) use of a patented catalyzed wall wick; (3) use of serrated-edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while still maintaining physical contact with the wall wick for electrolyte management; and (4) use of a floating rather than a fixed stack (state-of-the-art) to accommodate nickel electrode expansion due to charge/discharge cycling. The significant improvements resulting from these innovations are: extended cycle life; enhanced thermal, electrolyte, and oxygen management; and accommodation of nickel electrode expansion.

Thermal field monitoring and analysis of its influence on Direct Laser Deposition of single tracks of a nickel superalloy

NASA Astrophysics Data System (ADS)

Campanelli, Sabina L.; Angelastro, Andrea; Latte, Marco; Rizzo, Antonella; Palano, Fania

2018-02-01

Direct Laser Metal Deposition (DLMD) has been successfully applied for the coating or the repair of several kind of components, such as molds and dies. Recently, the aeronautical sector is also showing a high interest in this process for the repair of turbines and transmissions. However, technical requirements to be met for the repair of aeronautical components are much more stringent than standards of other industrial fields. Some of the deposited material defects that need to be carefully controlled are cracks and porosity, which largely depend on the temperature peaks and the cooling rates generated during the process. The aim of this work is to monitor the temperature field that was generated during the DLMD process, analyze its variation with some process parameters and study its effects on clad geometry and on dilution with the substrate. In this research, a number of experimental tests were designed for the deposition of single clads of a Nickel superalloy powder on an AISI 304 stainless steel substrate, using an Ytterbium fiber laser source. Temperature fields monitoring was carried out using a thermal camera capable of detecting temperatures up to 2500 °C.

Superalloy Lattice Block Structures

NASA Technical Reports Server (NTRS)

Nathal, M. V.; Whittenberger, J. D.; Hebsur, M. G.; Kantzos, P. T.; Krause, D. L.

2004-01-01

Initial investigations of investment cast superalloy lattice block suggest that this technology will yield a low cost approach to utilize the high temperature strength and environmental resistance of superalloys in lightweight, damage tolerant structural configurations. Work to date has demonstrated that relatively large superalloy lattice block panels can be successfully investment cast from both IN-718 and Mar-M247. These castings exhibited mechanical properties consistent with the strength of the same superalloys measured from more conventional castings. The lattice block structure also accommodates significant deformation without failure, and is defect tolerant in fatigue. The potential of lattice block structures opens new opportunities for the use of superalloys in future generations of aircraft applications that demand strength and environmental resistance at elevated temperatures along with low weight.

The key role of dislocation dissociation in the plastic behaviour of single crystal nickel-based superalloy with low stacking fault energy: Three-dimensional discrete dislocation dynamics modelling

NASA Astrophysics Data System (ADS)

Huang, Minsheng; Li, Zhenhuan

2013-12-01

To model the deformation of single crystal nickel based superalloys (SCNBS) with low stacking fault energy (SFE), three-dimensional discrete dislocation dynamics (3D-DDD) is extended by incorporating dislocation dissociation mechanism. The present 3D-DDD simulations show that, consistent with the existing TEM observation, the leading partial can enter the matrix channel efficiently while the trailing partial can hardly glide into it when the dislocation dissociation is taken into account. To determine whether the dislocation dissociation can occur or not, a critical percolation stress (CPS) based criterion is suggested. According to this CPS criterion, for SCNBS there exists a critical matrix channel width. When the channel width is lower than this critical value, the dislocation tends to dissociate into an extended configuration and vice versa. To clarify the influence of dislocation dissociation on CPS, the classical Orowan formula is improved by incorporating the SFE. Moreover, the present 3D-DDD simulations also show that the yielding stress of SCNBSs with low SFE may be overestimated up to 30% if the dislocation dissociation is ignored. With dislocation dissociation being considered, the size effect due to the width of γ matrix channel and the length of γ‧ precipitates on the stress-strain responses of SCNBS can be enhanced remarkably. In addition, due to the strong constraint effect by the two-phase microstructure in SCNBS, the configuration of formed junctions is quite different from that in single phase crystals such as Cu. The present results not only provide clear understanding of the two-phase microstructure levelled microplastic mechanisms in SCNBSs with low SFE, but also help to develop new continuum-levelled constitutive laws for SCNBSs.

Advanced nickel base alloys for high strength, corrosion applications

DOEpatents

Flinn, J.E.

1998-11-03

Improved nickel-base alloys of enhanced strength and corrosion resistance, produced by atomization of an alloy melt under an inert gas atmosphere and of composition 0--20Fe, 10--30Cr, 2--12Mo, 6 max. Nb, 0.05--3 V, 0.08 max. Mn, 0.5 max. Si, less than 0.01 each of Al and Ti, less than 0.05 each of P and S, 0.01--0.08C, less than 0.2N, 0.1 max. 0, bal. Ni. 3 figs.

On the Influence of Nb/Ti Ratio on Environmentally-Assisted Crack Growth in High-Strength Nickel-Based Superalloys

NASA Astrophysics Data System (ADS)

Németh, A. A. N.; Crudden, D. J.; Collins, D. M.; Kuksenko, V.; Liebscher, C. H.; Armstrong, D. E. J.; Wilkinson, A. J.; Reed, R. C.

2018-05-01

The effect of Nb/Ti ratio on environmentally-assisted crack growth of three prototype Ni-based superalloys is studied. For these alloys, the yield strength is unaltered with increasing Nb/Ti ratio due to an increase in grain size. This situation has allowed the rationalization of the factors influencing damage tolerance at 700 °C. Primary intergranular cracks have been investigated using energy-dispersive X-ray spectroscopy in a scanning transmission electron microscope and the analysis of electron back-scatter diffraction patterns. Any possible detrimental effect of Nb on the observed crack tip damage due to Nb-rich oxide formation is not observed. Instead, evidence is presented to indicate that the tertiary γ'-precipitates are dissolving ahead of the crack consistent with the formation of oxides such as alumina and rutile. Our results have implications for alloy design efforts; at any given strength level, both more and less damage-tolerant variants of these alloys can be designed.

Fiber-reinforced superalloy composites provide an added performance edge

NASA Technical Reports Server (NTRS)

Petrasek, D. W.; Mcdaniels, D. L.; Westfall, L. J.; Stephens, J. R.

1986-01-01

Fiber reinforcements are being explored as a means to increasing the performance of superalloys past 980 C. Fiber-reinforced superalloys (FRS), particularly tungsten FRS (TFRS) are candidate materials for rocket-engine turbopump blades for advanced Shuttle engines and in airbreathing and other rocket engines. Refractory metal wires are the reinforcement of choice due to tolerance to fiber/matrix interactions. W alloy fibers have a maximum tensile strength of 2165 MPa at 1095 C and a 100 hr creep rupture strength at stresses up to 1400 MPa. A TFRS has the potential of a service temperature 110 C over the strongest superalloy. Manufacturing processes being evaluated to realize the FRS components are summarized, together with design features which will be introduced in turbine blades to take advantage of the FRS materials and to extend their surface life.

Synthesis of advanced aluminide intermetallic coatings by low-energy Al-ion radiation

NASA Astrophysics Data System (ADS)

Shen, Mingli; Gu, Yan; Zhao, Panpan; Zhu, Shenglong; Wang, Fuhui

2016-05-01

Metals that work at high temperatures (for instance, superalloys in gas-turbines) depend on thermally grown oxide (TGO, commonly alumina) to withstand corrosion attack. Nickel Aluminide (NiAl) as one superior alumina TGO former plays an important role in protective coatings for turbine blades in gas-turbine engines used for aircraft propulsion and power generation. Lowering TGO growth rate is essentially favored for offering sustainable protection, especially in thermal barrier coatings (TBC). However, it can only be achieved currently by a strategy of adding the third element (Pt or reactive elements) into NiAl during traditional diffusion- or deposition-based synthesis of the coating. Here we present a highly flexible Al-ion radiation-based synthesis of advanced NiAl coatings, achieving low TGO growth rate without relying on the third element addition. Our results expand the strategy for lowering TGO growth rate and demonstrate potentials for ion radiation in advancing materials synthesis.

Synthesis of advanced aluminide intermetallic coatings by low-energy Al-ion radiation.

PubMed

Shen, Mingli; Gu, Yan; Zhao, Panpan; Zhu, Shenglong; Wang, Fuhui

2016-05-19

Metals that work at high temperatures (for instance, superalloys in gas-turbines) depend on thermally grown oxide (TGO, commonly alumina) to withstand corrosion attack. Nickel Aluminide (NiAl) as one superior alumina TGO former plays an important role in protective coatings for turbine blades in gas-turbine engines used for aircraft propulsion and power generation. Lowering TGO growth rate is essentially favored for offering sustainable protection, especially in thermal barrier coatings (TBC). However, it can only be achieved currently by a strategy of adding the third element (Pt or reactive elements) into NiAl during traditional diffusion- or deposition-based synthesis of the coating. Here we present a highly flexible Al-ion radiation-based synthesis of advanced NiAl coatings, achieving low TGO growth rate without relying on the third element addition. Our results expand the strategy for lowering TGO growth rate and demonstrate potentials for ion radiation in advancing materials synthesis.

Synthesis of advanced aluminide intermetallic coatings by low-energy Al-ion radiation

PubMed Central

Shen, Mingli; Gu, Yan; Zhao, Panpan; Zhu, Shenglong; Wang, Fuhui

2016-01-01

Metals that work at high temperatures (for instance, superalloys in gas-turbines) depend on thermally grown oxide (TGO, commonly alumina) to withstand corrosion attack. Nickel Aluminide (NiAl) as one superior alumina TGO former plays an important role in protective coatings for turbine blades in gas-turbine engines used for aircraft propulsion and power generation. Lowering TGO growth rate is essentially favored for offering sustainable protection, especially in thermal barrier coatings (TBC). However, it can only be achieved currently by a strategy of adding the third element (Pt or reactive elements) into NiAl during traditional diffusion- or deposition-based synthesis of the coating. Here we present a highly flexible Al-ion radiation-based synthesis of advanced NiAl coatings, achieving low TGO growth rate without relying on the third element addition. Our results expand the strategy for lowering TGO growth rate and demonstrate potentials for ion radiation in advancing materials synthesis. PMID:27194417

Design of Modern High Nb-Content gamma-gamma' Ni-Base Superalloys

NASA Astrophysics Data System (ADS)

Antonov, Stoichko

Certain elemental additions to Ni-base superalloys can significantly improve properties when added in high contents, but can quickly deteriorate the high temperature structural integrity and stability of the alloy, when solubility limits are exceeded and secondary phases are formed. Improved understanding of solubility limits of various elements in high refractory content Ni-base supralloys is therefore essential to improved alloy design. The morphology, formation, and composition of precipitate phases in a number of experimental alloys spanning a broad range of compositions were explored and compositional relationships were developed. The effect of increasing Nb alloying additions on formation and long term stability of topologically close packed (TCP) phases, as well as assessment of grain boundary phase compositions and local segregation along it before and after a 1000 hour thermal exposure at 800°C, was studied via electron microscopy and atom probe tomography (APT). Beneficial secondary phase precipitation, such as carbides and borides, was also studied through B, Hf and C doping. Elemental boron was observed to segregate to the grain boundary and phase interfaces, but did not form borides. APT studies on MC carbides of the alloys revealed the formation kinetics and morphological differences between NbC and Hf doped NbC, which were further explained using density functional theory (DFT) calculations of the formation energies of different facets of the MC carbide. Detailed electron microscopy and APT techniques were then used to systematically quantify the chemical and morphological instabilities that occur during aging of polycrystalline γ-γ' Ni-base superalloys containing elevated levels of refractory alloying additions. The morphological changes and splitting phenomenon associated with the secondary γ' precipitates were related to the discrete chemical compositions of the secondary and tertiary γ' along with the phase compositions of the γ matrix and

NASA/ORNL/AFRL Project Work on EBM LSHR: Additive Manufacturing of High-Temperature Gamma-Prime Strengthened Ni-Based Superalloys

NASA Technical Reports Server (NTRS)

Sudbrack, Chantal K.; Kirka, Michael M.; Dehoff, Ryan R.; Carter, Robert W.; Semiatin, Sheldon L.; Gabb, Timothy P.

2016-01-01

Powder-bed fabrication of aerospace alloys may revolutionize production by eliminating the need for extensive machining and expensive tooling. Heated-bed electron-beam melting (EBM) offers advantages over non-heated laser additive manufacturing (AM) methods, including lower residual stress, reduced risk of contamination, slower cooling rates, and faster build times. NASA Glenn Research Center has joint project work with Oak Ridge National Lab and the Air Force Research Laboratory to explore the feasibility of fabricating advanced Ni-based gamma-prime superalloys with EBM AM.

Influence of a magnetic field during directional solidification of MAR-M 246 + Hf superalloy

NASA Technical Reports Server (NTRS)

Andrews, J. Barry; Alter, Wendy; Schmidt, Dianne

1991-01-01

An area that has been almost totally overlooked in the optimization of properties in directionally solidified superalloys is the control of microstructural features through the application of a magnetic field during solidification. The influence of a magnetic field on the microstructural features of a nickel-base superalloys is investigated. Studies were performed on the dendritic MAR-M 246+Hf alloy, which was solidified under both a 5 K gauss magnetic field and under no-applied-field conditions. The possible influences of the magnetic field on the solidification process were observed by studying variations in microstructural features including volume fraction, surface area, number, and shape of the carbide particles. Stereological factors analyzed also included primary and secondary dendrite arm spacing and the volume fraction of the interdendritic eutectic constituent. Microprobe analysis was performed to determine the chemistry of the carbides, dendrites, and interdendritic constituents, and how it varied between field and no-field solidification samples. Experiments involving periodic application and removal of the magnetic field were also performed in order to permit a comparison with structural variations observed in a MAR-M 246+Hf alloy solidified during KC-135 high-g, low-g maneuvers.

Microstructural Evaluation of Forging Parameters for Superalloy Disks

NASA Technical Reports Server (NTRS)

Falsey, John R.

2004-01-01

Forgings of nickel base superalloy were formed under several different strain rates and forging temperatures. Samples were taken from each forging condition to find the ASTM grain size, and the as large as grain (ALA). The specimens were mounted in bakelite, polished, etched and then optical microscopy was used to determine grain size. The specimens ASTM grain sizes from each forging condition were plotted against strain rate, forging temperature, and presoak time. Grain sizes increased with increasing forging temperature. Grain sizes also increased with decreasing strain rates and increasing forging presoak time. The ALA had been determined from each forging condition using the ASTM standard method. Each ALA was compared with the ASTM grain size of each forging condition to determine if the grain sizes were uniform or not. The forging condition of a strain rate of .03/sec and supersolvus heat treatment produced non uniform grains indicated by critical grain growth. Other anomalies are noted as well.

Orientation and temperature dependence of some mechanical properties of the single-crystal nickel-base superalloy Rene N4. III - Tension-compression anisotropy

NASA Technical Reports Server (NTRS)

Miner, R. V.; Gabb, T. P.; Gayda, J.; Hemker, K. J.

1986-01-01

Single crystal superalloy specimens with various crystallographic directions along their axes were tested in compression at room temperature, 650, 760, 870, and 980 deg C. These results are compared with the tensile behavior studied previously. The alloy, Rene N4, was developed.

Advances in lightweight nickel electrode technology

NASA Technical Reports Server (NTRS)

Coates, Dwaine; Paul, Gary; Daugherty, Paul

1989-01-01

Studies are currently underway to further the development of lightweight nickel electrode technology. Work is focused primarily on the space nickel-hydrogen system and nickel-iron system but is also applicable to the nickel-cadmium and nickel-zinc systems. The goal is to reduce electrode weight while maintaining or improving performance, thereby increasing electrode energy density. Two basic electrode structures are being investigated. The first is the traditional nickel sponge produced from sintered nickel-carbonyl powder. The second is a new material for this application which consists of a non-woven mat of nickel fiber. Electrodes are being manufactured, tested, and evaluated at the electrode and cell level.

Advances in lightweight nickel electrode technology

NASA Technical Reports Server (NTRS)

Coates, Dwaine; Paul, Gary; Wheeler, James R.; Daugherty, Paul

1989-01-01

Studies are currently underway to further the development of lightweight nickel electrode technology. Work is focused primarily on the space nickel-hydrogen system and nickel-iron system but is also applicable to the nickel-cadmium and nickel-zinc systems. The goal is to reduce electrode weight while maintaining or improving performance thereby increasing electrode energy density. Two basic electrode structures are being investigated. The first is the traditional nickel sponge produced from sintered nickel-carbonyl powder and the second is a new material for this application which consists of a non-woven mat of nickel fiber. Electrodes are being manufactured, tested and evaluated at the electrode and cell level.

Phase Stability of a Powder Metallurgy Disk Superalloy

NASA Technical Reports Server (NTRS)

Gabb, Timothy P.; Gayda, John; Kantzos, P.; Telesman, Jack; Gang, Anita

2006-01-01

Advanced powder metallurgy superalloy disks in aerospace turbine engines now entering service can be exposed to temperatures approaching 700 C, higher than those previously encountered. They also have higher levels of refractory elements, which can increase mechanical properties at these temperatures but can also encourage phase instabilities during service. Microstructural changes including precipitation of topological close pack phase precipitation and coarsening of existing gamma' precipitates can be slow at these temperatures, yet potentially significant for anticipated disk service times exceeding 1,000 h. The ability to quantify and predict such potential phase instabilities and degradation of capabilities is needed to insure structural integrity and air worthiness of propulsion systems over the full life cycle. A prototypical advanced disk superalloy was subjected to high temperature exposures, and then evaluated. Microstructural changes and corresponding changes in mechanical properties were quantified. The results will be compared to predictions of microstructure modeling software.

Development of superalloys by powder metallurgy for use at 1000 - 1400 F

NASA Technical Reports Server (NTRS)

Calhoun, C. D.

1971-01-01

Consolidated powders of four nickel-base superalloys were studied for potential application as compressor and turbine discs in jet engines. All of the alloys were based on the Rene' 95 chemistry. Three of these had variations in carbon and A12O3 contents, and the fourth alloy was chemically modified to a higher volume fraction. The A12O3 was added by preoxidation of the powders prior to extrusion. Various levels of four experimental factors (1) alloy composition, (2) grain size, (3) thermomechanical processing, and (4) room temperature deformation plus final age were evaluated by tensile and stress rupture testing at 1200 F. Various levels of the four factors were assumed in order to construct the statistically-designed experiment, but the actual levels investigated were established in preliminary studies that preceded the statistical process development study.

The High Temperature Tensile and Creep Behaviors of High Entropy Superalloy.

PubMed

Tsao, Te-Kang; Yeh, An-Chou; Kuo, Chen-Ming; Kakehi, Koji; Murakami, Hideyuki; Yeh, Jien-Wei; Jian, Sheng-Rui

2017-10-04

This article presents the high temperature tensile and creep behaviors of a novel high entropy alloy (HEA). The microstructure of this HEA resembles that of advanced superalloys with a high entropy FCC matrix and L1 2 ordered precipitates, so it is also named as "high entropy superalloy (HESA)". The tensile yield strengths of HESA surpass those of the reported HEAs from room temperature to elevated temperatures; furthermore, its creep resistance at 982 °C can be compared to those of some Ni-based superalloys. Analysis on experimental results indicate that HESA could be strengthened by the low stacking-fault energy of the matrix, high anti-phase boundary energy of the strengthening precipitate, and thermally stable microstructure. Positive misfit between FCC matrix and precipitate has yielded parallel raft microstructure during creep at 982 °C, and the creep curves of HESA were dominated by tertiary creep behavior. To the best of authors' knowledge, this article is the first to present the elevated temperature tensile creep study on full scale specimens of a high entropy alloy, and the potential of HESA for high temperature structural application is discussed.

Fiber-Reinforced Superalloys For Rocket Engines

NASA Technical Reports Server (NTRS)

Lewis, Jack R.; Yuen, Jim L.; Petrasek, Donald W.; Stephens, Joseph R.

1990-01-01

Report discusses experimental studies of fiber-reinforced superalloy (FRS) composite materials for use in turbine blades in rocket engines. Intended to withstand extreme conditions of high temperature, thermal shock, atmospheres containing hydrogen, high cycle fatigue loading, and thermal fatigue, which tax capabilities of even most-advanced current blade material - directionally-solidified, hafnium-modified MAR M-246 {MAR M-246 (Hf) (DS)}. FRS composites attractive combination of properties for use in turbopump blades of advanced rocket engines at temperatures from 870 to 1,100 degrees C.

Dendrite segregation in Ni3Al-based intermetallic single crystals alloyed with Cr, Mo, W, Ti, Co, and Re

NASA Astrophysics Data System (ADS)

Drozdov, A. A.; Povarova, K. B.; Morozov, A. E.; Antonova, A. V.; Bulakhtina, M. A.; Alad'ev, N. A.

2015-07-01

The character of dendrite segregation in Ni3Al-based intermetallic VKNA-type alloy single crystals with a dendritic-cellular structure is studied. Distribution coefficient k d of an alloying element (AE) in the alloy during solidification k d = c d.a.I/ c 0 ( c 0 is the AE content in the alloy (liquid phase composition), c d.a.I is the AE content in primary dendrite arms of the alloy (in the solid phase)) and segregation coefficient k s = c d.a.I/ c i.d ( c i.d is the AE content in the interdendritic space) have been found. A comparative study of the dendrite segregation parameters in VKNA-nype Ni3Al-based intermetallic alloys and the well-known ZhS36-type nickel superalloy shows that the intermetallic alloys satisfy to the rule deduced for two- and three-component nickel-based superalloys: if an introduced AE increases the melting temperature of the basic metal, we have k d > 1 (Co, W, Re); if it decreases the melting temperature, we have k d < 1 (Al, Ti, Cr, Mo). Dendrite segregation coefficients k s are dependent on the proportion of the AE contents in the alloys. In nickel superalloys, the dendrite segregation of aluminum, tungsten, and rhenium is higher than that in the intermetallic alloys. The dendrite segregation coefficients of tungsten and rhenium is higher by a factor of 1.5-2 than that in the VKNA-type intermetallic alloys with a low content of refractory metals. This can be due to the retardation of diffusion of refractory metals in the solid phase of a nickel superalloy highly alloyed with these elements.

Effects of a High Magnetic Field on the Microstructure of Ni-Based Single-Crystal Superalloys During Directional Solidification

NASA Astrophysics Data System (ADS)

Xuan, Weidong; Lan, Jian; Liu, Huan; Li, Chuanjun; Wang, Jiang; Ren, Weili; Zhong, Yunbo; Li, Xi; Ren, Zhongming

2017-08-01

High magnetic fields are widely used to improve the microstructure and properties of materials during the solidification process. During the preparation of single-crystal turbine blades, the microstructure of the superalloy is the main factor that determines its mechanical properties. In this work, the effects of a high magnetic field on the microstructure of Ni-based single-crystal superalloys PWA1483 and CMSX-4 during directional solidification were investigated experimentally. The results showed that the magnetic field modified the primary dendrite arm spacing, γ' phase size, and microsegregation of the superalloys. In addition, the size and volume fractions of γ/ γ' eutectic and the microporosity were decreased in a high magnetic field. Analysis of variance (ANOVA) results showed that the effect of a high magnetic field on the microstructure during directional solidification was significant ( p < 0.05). Based on both experimental results and theoretical analysis, the modification of microstructure was attributed to thermoelectric magnetic convection occurring in the interdendritic regions under a high magnetic field. The present work provides a new method to optimize the microstructure of Ni-based single-crystal superalloy blades by applying a high magnetic field.

Preliminary Investigations of Joining Technologies for Attaching Refractory Metals to Ni-Based Superalloys

NASA Technical Reports Server (NTRS)

Gould, Jerry E.; Ritzert, Frank J.; Loewenthal, William S.

2006-01-01

In this study, a range of joining technologies has been investigated for creating attachments between refractory metal and Ni-based superalloys. Refractory materials of interest include Mo-47%Re, T-111, and Ta-10%W. The Ni-based superalloys include Hastelloy X and MarM 247. During joining with conventional processes, these materials have potential for a range of solidification and intermetallic formation-related defects. For this study, three non-conventional joining technologies were evaluated. These included inertia welding, electro-spark deposition (ESD) welding, and magnetic pulse welding (MPW). The developed inertia welding practice closely paralleled that typically used for the refractory metals alloys. Metallographic investigations showed that forging during inertia welding occurred predominantly on the nickel base alloy side. It was also noted that at least some degree of forging on the refractory metal side of the joint was necessary to achieve consistent bonding. Both refractory metals were readily weldable to the Hastelloy X material. When bonding to the MarM 247, results were inconsistent. This was related to the higher forging temperatures of the MarM 247, and subsequent reduced deformation on that material during welding. ESD trials using a Hastelloy X filler were successful for all material combinations. ESD places down very thin (5- to 10- m) layers per pass, and interactions between the substrates and the fill were limited (at most) to that layer. For the refractory metals, the fill only appeared to wet the surface, with minimal dilution effects. Microstructures of the deposits showed high weld metal integrity with maximum porosity on the order of a few percent. Some limited success was also obtained with MPW. In these trials, only the T-111 tubes were used. Joints were possible for the T-111 tube to the Hastelloy X bar stock, but the stiffness of the tube (resisting collapse) necessitated the use of very high power levels. These power levels

Oxidation and the Effects of High Temperature Exposures on Notched Fatigue Life of an Advanced Powder Metallurgy Disk Superalloy

NASA Technical Reports Server (NTRS)

Sudbrack, Chantal K.; Draper, Susan L.; Gorman, Timothy T.; Telesman, Jack; Gab, Timothy P.; Hull, David R.

2012-01-01

Oxidation and the effects of high temperature exposures on notched fatigue life were considered for a powder metallurgy processed supersolvus heat-treated ME3 disk superalloy. The isothermal static oxidation response at 704 C, 760 C, and 815 C was consistent with other chromia forming nickel-based superalloys: a TiO2-Cr2O3 external oxide formed with a branched Al2O3 internal subscale that extended into a recrystallized - dissolution layer. These surface changes can potentially impact disk durability, making layer growth rates important. Growth of the external scales and dissolution layers followed a cubic rate law, while Al2O3 subscales followed a parabolic rate law. Cr- rich M23C6 carbides at the grain boundaries dissolved to help sustain Cr2O3 growth to depths about 12 times thicker than the scale. The effect of prior exposures was examined through notched low cycle fatigue tests performed to failure in air at 704 C. Prior exposures led to pronounced debits of up to 99 % in fatigue life, where fatigue life decreased inversely with exposure time. Exposures that produced roughly equivalent 1 m thick external scales at the various isotherms showed statistically equivalent fatigue lives, establishing that surface damage drives fatigue debit, not exposure temperature. Fractographic evaluation indicated the failure mode for the pre-exposed specimens involved surface crack initiations that shifted with exposure from predominately single intergranular initiations with transgranular propagation to multi-initiations from the cracked external oxide with intergranular propagation. Weakened grain boundaries at the surface resulting from the M23C6 carbide dissolution are partially responsible for the intergranular cracking. Removing the scale and subscale while leaving a layer where M23C6 carbides were dissolved did not lead to a significant fatigue life improvement, however, also removing the M23C6 carbide dissolution layer led to nearly full recovery of life, with a

Low Cost Heat Treatment Process for Production of Dual Microstructure Superalloy Disks

NASA Technical Reports Server (NTRS)

Gayda, John; Gabb, Tim; Kantzos, Pete; Furrer, David

2003-01-01

There are numerous incidents where operating conditions imposed on a component mandate different and distinct mechanical property requirements from location to location within the component. Examples include a crankshaft in an internal combustion engine, gears for an automotive transmission, and disks for a gas turbine engine. Gas turbine disks are often made from nickel-base superalloys, because these disks need to withstand the temperature and stresses involved in the gas turbine cycle. In the bore of the disk where the operating temperature is somewhat lower, the limiting material properties are often tensile and fatigue strength. In the rim of the disk, where the operating temperatures are higher than those of the bore, because of the proximity to the combustion gases, resistance to creep and crack growth are often the limiting properties.

Precision cast vs. wrought superalloys

NASA Technical Reports Server (NTRS)

Tien, J. K.; Borofka, J. C.; Casey, M. E.

1986-01-01

While cast polycrystalline superalloys recommend themselves in virtue of better 'buy-to-fly' ratios and higher strengthening gamma-prime volume fractions than those of wrought superalloys, the expansion of their use into such critical superalloy applications as gas turbine hot section components has been slowed by insufficient casting process opportunities for microstructural control. Attention is presently drawn, however, to casting process developments facilitating the production of defect-tolerant superalloy castings having improved fracture reliability. Integrally bladed turbine wheel and thin-walled turbine exhaust case near-net-shape castings have been produced by these means.

Advanced Stirling Duplex Materials Assessment for Potential Venus Mission Heater Head Application

NASA Technical Reports Server (NTRS)

Ritzert, Frank; Nathal, Michael V.; Salem, Jonathan; Jacobson, Nathan; Nesbitt, James

2011-01-01

This report will address materials selection for components in a proposed Venus lander system. The lander would use active refrigeration to allow Space Science instrumentation to survive the extreme environment that exists on the surface of Venus. The refrigeration system would be powered by a Stirling engine-based system and is termed the Advanced Stirling Duplex (ASD) concept. Stirling engine power conversion in its simplest definition converts heat from radioactive decay into electricity. Detailed design decisions will require iterations between component geometries, materials selection, system output, and tolerable risk. This study reviews potential component requirements against known materials performance. A lower risk, evolutionary advance in heater head materials could be offered by nickel-base superalloy single crystals, with expected capability of approximately 1100C. However, the high temperature requirements of the Venus mission may force the selection of ceramics or refractory metals, which are more developmental in nature and may not have a well-developed database or a mature supporting technology base such as fabrication and joining methods.

Rapid solidification and dynamic compaction of Ni-base superalloy powders

NASA Technical Reports Server (NTRS)

Field, R. D.; Hales, S. J.; Powers, W. O.; Fraser, H. L.

1984-01-01

A Ni-base superalloy containing 13Al-9Mo-2Ta (in at. percent) has been characterized in both the rapidly solidified condition and after dynamic compaction. Dynamically compacted specimens were examined in the as-compacted condition and observations related to current theories of interparticle bonding. In addition, the recrystallization behavior of the compacted material at relatively low temperature (about 0.5-0.75 Tm) was investigated.

New Mechanistic Models of Long Term Evolution of Microstructure and Mechanical Properties of Nickel Based Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kruzic, Jamie J.; Evans, T. Matthew; Greaney, P. Alex

The report describes the development of a discrete element method (DEM) based modeling approach to quantitatively predict deformation and failure of typical nickel based superalloys. A series of experimental data, including microstructure and mechanical property characterization at 600°C, was collected for a relatively simple, model solid solution Ni-20Cr alloy (Nimonic 75) to determine inputs for the model and provide data for model validation. Nimonic 75 was considered ideal for this study because it is a certified tensile and creep reference material. A series of new DEM modeling approaches were developed to capture the complexity of metal deformation, including cubic elasticmore » anisotropy and plastic deformation both with and without strain hardening. Our model approaches were implemented into a commercially available DEM code, PFC3D, that is commonly used by engineers. It is envisioned that once further developed, this new DEM modeling approach can be adapted to a wide range of engineering applications.« less

A status review of NASA's COSAM (Conservation Of Strategic Aerospace Materials) program

NASA Technical Reports Server (NTRS)

Stephens, J. R.

1982-01-01

The use and supply of strategic elements in nickel base superalloys for gas turbine engines are reviewed. Substitution of strategic elements, advanced processing concepts, and the identification of alternate materials are considered. Cobalt, tantalum, columbium, and chromium, the supplies of which are 91-100% imported, are the materials of major concern.

Application of superalloy powder metallurgy for aircraft engines

NASA Technical Reports Server (NTRS)

Dreshfield, R. L.; Miner, R. V., Jr.

1980-01-01

The results of the Materials for Advanced Turbine Engines (MATE) program initiated by NASA are presented. Mechanical properties comparisons are made for superalloy parts produced by as-HIP powder consolidation and by forging of HIP consolidated billets. The effect of various defects on the mechanical properties of powder parts are shown.

Materials review for improved automotive gas turbine engine. [superalloys, refractory alloys, and ceramics

NASA Technical Reports Server (NTRS)

Belleau, C.; Ehlers, W. L.; Hagen, F. A.

1978-01-01

The potential role of superalloys, refractory alloys, and ceramics in the hottest sections of engines operating with turbine inlet temperatures as high as 1370 C is examined. The convential superalloys, directionally solidified eutectics, oxide dispersion strenghened alloys, and tungsten fiber reinforced superalloys are reviewed and compared on the basis of maximum turbine blade temperature capability. Improved high temperature protective coatings and special fabrication techniques for these advanced alloys are discussed. Chromium, columbium, molybdenum, tantalum, and tungsten alloys are also reviewed. Molbdenum alloys are found to be the most suitable for mass produced turbine wheels. Various forms and fabrication processes for silicon nitride, silicon carbide, and SIALON's are investigated for use in highstress and medium stress high temperature environments.

A Platinum-Enriched gamma+gamma' Two-Phase Bond Coat on Ni-Base Superalloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhang, Ying; Pint, Bruce A; Haynes, James A

2005-01-01

Pt-enriched {gamma} + {gamma}{prime} two-phase coating was applied to directionally-solidified Ni-based superalloy Ren{acute e} 142 substrates with three different Hf levels (0.02, 0.76, and 1.37 wt.%). The coating was prepared by electroplating a thin layer of Pt on the superalloy followed by a diffusion treatment. The as-deposited coating exhibited a {gamma} + {gamma}{prime} two-phase microstructure with a major composition of Ni-16Al-18Pt-7Cr-9Co (in at.%) along with some incorporation of refractory elements from the substrates. Cyclic oxidation testing at 1100 C in air indicated improved oxidation resistance of the Ren{acute e} 142 alloys with the Pt-enriched {gamma} + {gamma}{prime} coatings. In addition,more » the oxidation resistance of both uncoated and coated alloys was proportional to the Hf content in the substrate. Compared with the single-phase {beta}-(Ni,Pt)Al coating, slightly higher mass gains and localized spallation were observed on the {gamma} + {gamma}{prime} two-phase coating, which might be due to the segregation of refractory elements and high sulfur levels in these superalloy substrates.« less

Tungsten fiber reinforced superalloy composite high temperature component design considerations

NASA Technical Reports Server (NTRS)

Winsa, E. A.

1982-01-01

Tungsten fiber reinforced superalloy composites (TFRS) are intended for use in high temperature turbine components. Current turbine component design methodology is based on applying the experience, sometimes semiempirical, gained from over 30 years of superalloy component design. Current composite component design capability is generally limited to the methodology for low temperature resin matrix composites. Often the tendency is to treat TFRS as just another superalloy or low temperature composite. However, TFRS behavior is significantly different than that of superalloys, and the high environment adds consideration not common in low temperature composite component design. The methodology used for preliminary design of TFRS components are described. Considerations unique to TFRS are emphasized.

A Coupled Creep Plasticity Model for Residual Stress Relaxation of a Shot Peened Nickel-Base Superalloy (Postprint)

DTIC Science & Technology

2008-09-01

titanium - and nickel-base alloys [1- 2,5- 6 ]. For applications that utilize aluminum and titanium alloys, subjected to moderate temperatures and...reaching the target stress for creep. 1e-9 1e-8 1e-7 1e- 6 1e-5 1e- 4 1e-3 1e-2 1e-1 1e-3 1e-2 1e-1 -1% Prestrain 0% Prestrain +1% Prestrain +5...was adapted to a rate-independent nonlinear isotropic-kinematic hardening model described by Dodds [30]. 10-9 10-8 10-7 10- 6 10-5 10- 4 10-3 10-2 10

Tensile and creep deformation of a newly developed Ni-Fe-based superalloy for 700 °C advanced ultra-supercritical boiler applications

NASA Astrophysics Data System (ADS)

Yuan, Y.; Zhong, Z. H.; Yu, Z. S.; Yin, H. F.; Dang, Y. Y.; Zhao, X. B.; Yang, Z.; Lu, J. T.; Yan, J. B.; Gu, Y.

2015-07-01

A new Ni-Fe-based superalloy, HT-X, has been developed for applications in 700 °C advanced ultra-supercritical (A-USC) boilers. The HT-X alloy is subjected to various heat treatments. Tensile tests are conducted at room temperature (RT), 700 °C and 750 °C. Creep tests are carried out under conditions of 700 °C/300 MPa and 750 °C/150 MPa. After aging treatment, the yield strength of the HT-X alloy at RT and 750 °C is 787 MPa and 624 MPa, respectively. When additional thermal exposure at 750 °C for 5400 h is applied, the yield strength is decreased to 656 MPa at RT and 480 MPa at 700 °C. For an aged specimen, the a/2<110>dislocation shearing process occurs when tensile testing is conducted at RT and 750 °C. As the γ' precipitate size increases in the specimen that is thermally exposed at 750 °C for 5400 h, Orowan bowing is the dominant dislocation process, and stacking faults develop in the γ' precipitates at both RT and 700 °C. Dislocation slip combined with climb is the dominant mechanism under the creep testing conditions. The factors that affect the mechanical properties and deformation mechanisms are discussed.

Determination of solute site occupancies within γ' precipitates in nickel-base superalloys via orientation-specific atom probe tomography

DOE PAGES

Meher, Subhashish; Rojhirunsakool, Tanaporn; Nandwana, Peeyush; ...

2015-04-28

In this study, the analytical limitations in atom probe tomography such as resolving a desired set of atomic planes, for solving complex materials science problems, have been overcome by employing a well-developed unique and reproducible crystallographic technique, involving synergetic coupling of orientation microscopy with atom probe tomography. The crystallographic information in atom probe reconstructions has been utilized to determine the solute site occupancies in Ni-Al-Cr based superalloys accurately. The structural information in atom probe reveals that both Al and Cr occupy the same sub-lattice within the L1 2-ordered g precipitates to form Ni 3(Al,Cr) precipitates in a Ni-14Al-7Cr(at.%) alloy. Interestingly,more » the addition of Co, which is a solid solution strengthener, to a Ni-14Al-7Cr alloy results in the partial reversal of Al site occupancy within g precipitates to form (Ni,Al) 3(Al,Cr,Co) precipitates. This unique evidence of reversal of Al site occupancy, resulting from the introduction of other solutes within the ordered structures, gives insights into the relative energetics of different sub-lattice sites when occupied by different solutes.« less

NICKEL-BASE ALLOY

DOEpatents

Inouye, H.; Manly, W.D.; Roche, T.K.

1960-01-19

A nickel-base alloy was developed which is particularly useful for the containment of molten fluoride salts in reactors. The alloy is resistant to both salt corrosion and oxidation and may be used at temperatures as high as 1800 deg F. Basically, the alloy consists of 15 to 22 wt.% molybdenum, a small amount of carbon, and 6 to 8 wt.% chromium, the balance being nickel. Up to 4 wt.% of tungsten, tantalum, vanadium, or niobium may be added to strengthen the alloy.

Superalloy Lattice Block Structures

NASA Technical Reports Server (NTRS)

Whittenberger, J. D.; Nathal, M. V.; Hebsur, M. G.; Kraus, D. L.

2003-01-01

In their simplest form, lattice block panels are produced by direct casting and result in lightweight, fully triangulated truss-like configurations which provide strength and stiffness [2]. The earliest realizations of lattice block were made from A1 and steels, primarily under funding from the US Navy [3]. This work also showed that the mechanical efficiency (eg., specific stiffness) of lattice block structures approached that of honeycomb structures [2]. The lattice architectures are also less anisotropic, and the investment casting route should provide a large advantage in cost and temperature capability over honeycombs which are limited to alloys that can be processed into foils. Based on this early work, a program was initiated to determine the feasibility of extending the high temperature superalloy lattice block [3]. The objective of this effort was to provide an alternative to intermetallics and composites in achieving a lightweight high temperature structure without sacrificing the damage tolerance and moderate cost inherent in superalloys. To establish the feasibility of the superalloy lattice block concept, work was performed in conjunction with JAMCORP, Inc. Billerica, MA, to produce a number of lattice block panels from both IN71 8 and Mar-M247.

Structural Performance of Inconel 625 Superalloy Brazed Joints

NASA Astrophysics Data System (ADS)

Chen, Jianqiang; Demers, Vincent; Cadotte, Eve-Line; Turner, Daniel; Bocher, Philippe

2017-02-01

The purpose of this work was to investigate tensile and fatigue behaviors of Inconel 625 superalloy brazed joints after transient liquid-phase bonding process. Brazing was performed in a vacuum furnace using a nickel-based filler metal in a form of paste to join wrought Inconel 625 plates. Mechanical tests were carried out on single-lap joints under various lap distance-to-thickness ratios. The fatigue crack initiation and crack growth modes were examined via metallographic analysis, and the effect of local stress on fatigue life was assessed by finite element simulations. The fatigue results show that fatigue strength and endurance limit increase with overlap distance, leading to a relatively large scatter of results. Fatigue cracks nucleated in the high-stressed region of the weld fillets from brittle eutectic phases or from internal brazing cavities. The present work proposes to rationalize the results by using the local stress at the brazing fillet. When using this local stress, all fatigue-obtained results find themselves on a single S- N curve, providing a design curve for any joint configuration in fatigue solicitation.

High temperature seals between ceramic separation membranes and super-alloy housing

NASA Technical Reports Server (NTRS)

Honea, G.; Sridhar, K. R.

1991-01-01

One of the concepts for oxygen production from Martian atmospheric carbon dioxide involves the use of tubular electrochemical membranes for oxygen separation. The tubular configuration offers the advantage of being able to separate the oxygen at pressures of up to 500 psi, thereby eliminating the need for a pre-liquefaction oxygen compressor. A key technology that has to be developed in order for the electrochemical separator to combine as a compressor is a high temperature static seal between the ceramic separation cell and the nickel-based super-alloy tube. Equipment was designed and fabricated to test the seals. Efforts are under way to develop a finite element model to study the thermal stresses at the joints and on the seal, and the optimal shape of the seal. The choice of seal materials and the technique to be used to fabricate the seals are also being investigated.

Thermal and Irradiation Creep Behavior of a Titanium Aluminide in Advanced Nuclear Plant Environments

NASA Astrophysics Data System (ADS)

Magnusson, Per; Chen, Jiachao; Hoffelner, Wolfgang

2009-12-01

Titanium aluminides are well-accepted elevated temperature materials. In conventional applications, their poor oxidation resistance limits the maximum operating temperature. Advanced reactors operate in nonoxidizing environments. This could enlarge the applicability of these materials to higher temperatures. The behavior of a cast gamma-alpha-2 TiAl was investigated under thermal and irradiation conditions. Irradiation creep was studied in beam using helium implantation. Dog-bone samples of dimensions 10 × 2 × 0.2 mm3 were investigated in a temperature range of 300 °C to 500 °C under irradiation, and significant creep strains were detected. At temperatures above 500 °C, thermal creep becomes the predominant mechanism. Thermal creep was investigated at temperatures up to 900 °C without irradiation with samples of the same geometry. The results are compared with other materials considered for advanced fission applications. These are a ferritic oxide-dispersion-strengthened material (PM2000) and the nickel-base superalloy IN617. A better thermal creep behavior than IN617 was found in the entire temperature range. Up to 900 °C, the expected 104 hour stress rupture properties exceeded even those of the ODS alloy. The irradiation creep performance of the titanium aluminide was comparable with the ODS steels. For IN617, no irradiation creep experiments were performed due to the expected low irradiation resistance (swelling, helium embrittlement) of nickel-base alloys.

The Microstructural Evolution of Haynes 282 Alloy During Long-Term Exposure Tests

NASA Astrophysics Data System (ADS)

Fu, Rui; Zhao, Shuangqun; Wang, Yanfeng; Li, Qiang; Ma, Yunhai; Lin, Fusheng; Chi, Chengyu

Haynes 282 alloy is a γ' precipitation strengthened nickel based superalloy designed by Haynes International Incorporation in 2005. This alloy is currently being evaluated for use as high temperature components at 700°C Advanced-Ultra Supercritical (A-USC)power plants, thus it is particularly important to have good creep property and microstructure stability.

The isothermal-oxidation behavior of several nickel-base single-crystal superalloys with and without coatings

DOE Office of Scientific and Technical Information (OSTI.GOV)

Goebel, M.; Rahmel, A.; Schuetze, M.

1993-04-01

Several commercial single-crystal superalloys (CMSX-2, CMSX-3, CMSX-4, CMSX-6, SRR 99) and some laboratory versions of one of them (CMSX-4) with various Y-additions were investigated concerning their oxidation resistance in air at temperatures between 800 and 1,200[degrees]C. The investigations also included two materials (CMSX-6, SRR 99) with an RT-22 coating. Weight change was recorded for times of up to 1,000 hr (in some cases up to 1,600 hr). Oxidized coatings and substrates were characterized by metallography, SEM, and microprobe analysis. Most of the alloys showed good oxidation resistance up to 1,000[degrees]C, while there was complete spalling during cooling after oxidation atmore » 1,150[degrees]C and 1,200[degrees]C for the uncoated and Y-free alloys. Coated alloys were superior, however the best behavior was shown by a laboratory version of CMSX-4 containing between 10 and 60 ppm Y. Interdiffusion at 1,000[degrees]C is tolerable for the coated alloys, but there was extremely rapid degradation of the coating by interdiffusion at 1,200[degrees]C. 20 refs., 26 figs., 6 tabs.« less

Plastic Flow and Microstructure Evolution during Thermomechanical Processing of a PM Nickel-Base Superalloy

NASA Astrophysics Data System (ADS)

Semiatin, S. L.; McClary, K. E.; Rollett, A. D.; Roberts, C. G.; Payton, E. J.; Zhang, F.; Gabb, T. P.

2013-06-01

Plastic flow and microstructure evolution during sub- and supersolvus forging and subsequent supersolvus heat treatment of the powder-metallurgy superalloy LSHR (low-solvus, high-refractory) were investigated to develop an understanding of methods that can be used to obtain a moderately coarse gamma grain size under well-controlled conditions. To this end, isothermal, hot compression tests were conducted over broad ranges of temperature [(1144 K to 1450 K) 871 °C to 1177 °C] and constant true strain rate (0.0005 to 10 s-1). At low temperatures, deformation was generally characterized by flow softening and dynamic recrystallization that led to a decrease in grain size. At high subsolvus temperatures and low strain rates, steady-state flow or flow hardening was observed. These latter behaviors were ascribed to superplastic deformation and microstructure evolution characterized by a constant grain size or concomitant dynamic grain growth, respectively. During supersolvus heat treatment following subsolvus deformation, increases in grain size whose magnitude was a function of the prior deformation conditions were noted. A transition in flow behavior from superplastic to nonsuperplastic and the development during forging at a high subsolvus temperature of a wide (possibly bi- or multimodal) gamma-grain-size distribution having some large grains led to a substantially coarser grain size during supersolvus annealing in comparison to that produced under all other forging conditions.

Materials for advanced rocket engine turbopump turbine blades

NASA Technical Reports Server (NTRS)

Chandler, W. T.

1985-01-01

A study program was conducted to identify those materials that will provide the greatest benefits as turbine blades for advanced liquid propellant rocket engine turbines and to prepare technology plans for the development of those materials for use in the 1990 through 1995 period. The candidate materials were selected from six classes of materials: single-crystal (SC) superalloys, oxide dispersion-strengthened (ODS) superalloys, rapid solidification processed (RSP) superalloys, directionally solidified eutectic (DSE) superalloys, fiber-reinforced superalloy (FRS) composites, and ceramics. Properties of materials from the six classes were compiled and evaluated and property improvements were projected approximately 5 years into the future for advanced versions of materials in each of the six classes.

A Multi-Scale Simulation Approach to Deformation Mechanism Prediction in Superalloys

NASA Astrophysics Data System (ADS)

Lv, Duchao

High-temperature alloys in general and superalloys in particular are crucial for manufacturing gas turbines for aircraft and power generators. Among the superalloy family, the Ni-based superalloys are the most frequently used due to their excellent strength-to-weight ratio. Their strength results from their ordered intermetallic phases (precipitates), which are relatively stable at elevated temperatures. The major deformation processes of Ni-based and Co-based superalloys are precipitate shearing and Orowan looping. The key to developing physics-based models of creep and yield strength of aircraft engine components is to understand the two deformation mechanisms mentioned above. Recent discoveries of novel dislocation structures and stacking-fault configurations in deformed superalloys implied that the traditional anti-phase boundary (APB)-type, yield-strength model is unable to explain the shearing mechanisms of the gamma" phase in 718-type (Ni-based) superalloys. While the onset of plastic deformation is still related to the formation of highly-energetic stacking faults, the physics-based yield strength prediction requires that the novel dislocation structure and the correct intermediate stacking-fault be considered in the mathematical expressions. In order to obtain the dependence of deformation mechanisms on a materials chemical composition, the relationship between the generalized-stacking-fault (GSF) surface and its chemical composition must be understood. For some deformation scenarios in which one precipitate phase and one mechanism are dominant (e.g., Orowan looping), their use in industry requires a fast-acting model that can capture the features of the deformation (e.g., the volume fraction of the sheared matrix) and reduces lost time by not repeating fine-scale simulations. The objective of this thesis was to develop a multi-scale, physics-based simulation approach that can be used to optimize existing superalloys and to accelerate the design of new

Initial performance of advanced designs for IPV nickel-hydrogen cells

NASA Technical Reports Server (NTRS)

Smithrick, John J.

1986-01-01

Advanced designs for individual pressure vessel nickel-hydrogen cells have been conceived which should improve the cycle life at deep depths-of-discharge and improve thermal management. Features of the designs which are new and not incorporated in either of the contemporary cells (Air Force/Hughes, Comsat) are: (1) use of alternate methods of oxygen recombination, (2) use of serrated edge separators to facilitate movement of gas within the cell while still maintaining required physical contact with the wall wick, and (3) use of an expandable stack to accommodate some of the nickel electrode expansion. The designs also consider electrolyte volume requirements over the life of the cells, and are fully compatible with the Air Force/Hughes design.

Initial performance of advanced designs for IPV nickel-hydrogen cells

NASA Technical Reports Server (NTRS)

Smithrick, J. J.

1985-01-01

Advanced designs for individual pressure vessel nickel hydrogen cells were conceived which should improve the life cycle at deep depths of discharge and improve thermal management. Features of the designs which are new and not incorporated in either of the contemporary cells (Air Force/Hughes, Comsat) are: (1) the use of alternate methods of oxygen recombination, (2) use of serrated edge separators to facilitate movement of gas within the cell while still maintaining required physical contact with the wall wick, and (3) use of an expandable stack to accommodate some of the nickel electrode expansion. The designs also consider electrolyte volume requirements over the life of the cells, and are fully compatible with the Air Force/Hughes design.

Effect of LEO cycling on 125 Ah advanced design IPV nickel-hydrogen battery cells

NASA Technical Reports Server (NTRS)

Smithrick, John J.; Hall, Stephen W.

1990-01-01

An advanced 125 Ah individual pressure vessel (IPV) nickel-hydrogen cell was designed. The primary function of the advanced cell, is to store and deliver energy for long term, low earth-orbit (LEO) spacecraft missions. The new features of this design are: (1) use of 26 percent rather than 31 percent potassium hydroxide (KOH) electrolyte, (2) use of a patented catalyzed wall wick, (3) use of serrated edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while still maintaining physical contact with the wall wick for electrolyte management, and (4) use of a floating rather than a fixed stack (state-of-the-art) to accommodate nickel electrode expansion. Six 125 Ah flight cells based on this design were fabricated by Eagle-Picher. Three of the cells contain all of the advanced features (test cells) and three are the same as the test cells except they don't have catalyst on the wall wick (control cells). All six cells are in the process of being evaluated in a LEO cycle life test. The cells have accumulated about 4700 LEO cycles (60 percent DOD 10 C). There have been no cell failures, the catalyzed wall wick cells however, are performing better.

Effect of LEO cycling on 125 Ah advanced design IPV nickel-hydrogen battery cells

NASA Technical Reports Server (NTRS)

Smithrick, John J.; Hall, Stephen W.

1990-01-01

An advanced 125 Ah individual pressure vessel (IPV) nickel-hydrogen cell was designed. The primary function of the advanced cell is to store and deliver energy for long-term, low earth-orbit (LEO) spacecraft missions. The new features of this design are: (1) use of 26 percent rather than 31 percent potassium hydroxide (KOH) electrolyte, (2) use of a patented catalyzed wall wick, (3) use of serrated-edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while still maintaining physical contact with the wall wick for electrolyte management, and (4) use of a floating rather than a fixed stack (state-of-the-art) to accommodate nickel electrode expansion. Six 125-Ah flight cells based on this design were fabricated by Eagle-Picher. Three of the cells contain all of the advanced features (test cells) and three are the same as the test cells except they don't have catalyst on the wall wick (control cells). All six cells are in the process of being evaluated in a LEO cycle life test. The cells have accumulated about 4700 LEO cycles (60 percent DOD 10 C). There have been no cell failures; the catalyzed wall wick cells, however, are performing better.

Design of high entropy alloys based on the experience from commercial superalloys

NASA Astrophysics Data System (ADS)

Wang, Z.; Huang, Y.; Wang, J.; Liu, C. T.

2015-01-01

High entropy alloys (HEAs) have been drawing increasing attention recently and gratifying results have been obtained. However, the existing metallurgic rules of HEAs could not provide specific information of selecting candidate alloys for structural applications. Our brief survey reveals that many commercial superalloys have medium and even to high configurational entropies. The experience of commercial superalloys provides a clue for helping us in the development of HEAs for structural applications.

Creep Crack Initiation and Growth Behavior for Ni-Base Superalloys

NASA Astrophysics Data System (ADS)

Nagumo, Yoshiko; Yokobori, A. Toshimitsu, Jr.; Sugiura, Ryuji; Ozeki, Go; Matsuzaki, Takashi

The structural components which are used in high temperature gas turbines have various shapes which may cause the notch effect. Moreover, the site of stress concentration might have the heterogeneous microstructural distribution. Therefore, it is necessary to clarify the creep fracture mechanism for these materials in order to predict the life of creep fracture with high degree of accuracy. In this study, the creep crack growth tests were performed using in-situ observational testing machine with microscope to observe the creep damage formation and creep crack growth behavior. The materials used are polycrystalline Ni-base superalloy IN100 and directionally solidified Ni-base superalloy CM247LC which were developed for jet engine turbine blades and gas turbine blades in electric power plants, respectively. The microstructural observation of the test specimens was also conducted using FE-SEM/EBSD. Additionally, the analyses of two-dimensional elastic-plastic creep finite element using designed methods were conducted to understand the effect of microstructural distribution on creep damage formation. The experimental and analytical results showed that it is important to determine the creep crack initiation and early crack growth to predict the life of creep fracture and it is indicated that the highly accurate prediction of creep fracture life could be realized by measuring notch opening displacement proposed as the RNOD characteristic.

Testing superalloys at 2000 (1367) and 2200 F (1478 K) in a Mach 4.6 airstream

NASA Technical Reports Server (NTRS)

Land, D. W.; Williams, R. R.; Rinehart, W. A.

1972-01-01

Seven superalloy models were tested in a plasma arc tunnel facility. The test models were 3 in. (7.62cm) square flat surfaces (nominally 0.01 to 0.02 in. (0.0254 to 0.0508 cm) thick) held in a water-cooled wedge holder at a 60 deg (1.05 rad) angle of attack. The models were cycled 25 times (two were cycled 50 times) for 10 min each cycle in a Mach 4.6 test stream with the model leading edge temperature maintained at 2200 F (1478 K) (one at 2000 F (1367 K)). Backface temperatures were measured with four platinum-platinum 10% rhodium thermocouples and the front surface temperatures with an optical pyrometer. Four different nickel base alloy materials and one cobalt material were evaluated.

Transverse and longitudinal tensile properties at 760 C of several oxide dispersion strengthened nickel-base alloys

NASA Technical Reports Server (NTRS)

Anglin, A. E., Jr.

1979-01-01

The transverse and longitudinal tensile properties of the oxide dispersion strengthened nickel-base alloys were determined at 760 C. The alloys with small amounts of gamma prime have strength levels suitable for turbine vane applications, while other highly alloyed, gamma prime strengthened superalloys have strengths typical of turbine blade materials. These alloys were produced by mechanical alloying and extrusion and the turbine blade alloys were also directionally recrystallized. Resultant grain aspect ratios varied from 1:1 to over 20:1. Longitudinal tensile strengths ranged from 285 to 1175 MPa, while longitudinal elongations were in excess of 4 percent for all alloys. Transverse tensile strengths were comparable to longitudinal strengths, but transverse ductility levels were generally less than 2 percent elongation. Tensile and yield strengths increased with increasing strain rate over the range 0.001 to 0.05 per second. Ductility in both orientations was not strain rate sensitive but could be related to grain size and grain aspect ratio.

Potassium Sodium Niobate-Based Lead-Free Piezoelectric Multilayer Ceramics Co-Fired with Nickel Electrodes.

PubMed

Kawada, Shinichiro; Hayashi, Hiroyuki; Ishii, Hideki; Kimura, Masahiko; Ando, Akira; Omiya, Suetake; Kubodera, Noriyuki

2015-11-03

Although lead-free piezoelectric ceramics have been extensively studied, many problems must still be overcome before they are suitable for practical use. One of the main problems is fabricating a multilayer structure, and one solution attracting growing interest is the use of lead-free multilayer piezoelectric ceramics. The paper reviews work that has been done by the authors on lead-free alkali niobate-based multilayer piezoelectric ceramics co-fired with nickel inner electrodes. Nickel inner electrodes have many advantages, such as high electromigration resistance, high interfacial strength with ceramics, and greater cost effectiveness than silver palladium inner electrodes. However, widely used lead zirconate titanate-based ceramics cannot be co-fired with nickel inner electrodes, and silver palladium inner electrodes are usually used for lead zirconate titanate-based piezoelectric ceramics. A possible alternative is lead-free ceramics co-fired with nickel inner electrodes. We have thus been developing lead-free alkali niobate-based multilayer ceramics co-fired with nickel inner electrodes. The normalized electric-field-induced thickness strain ( S max / E max ) of a representative alkali niobate-based multilayer ceramic structure with nickel inner electrodes was 360 pm/V, where S max denotes the maximum strain and E max denotes the maximum electric field. This value is about half that for the lead zirconate titanate-based ceramics that are widely used. However, a comparable value can be obtained by stacking more ceramic layers with smaller thicknesses. In the paper, the compositional design and process used to co-fire lead-free ceramics with nickel inner electrodes are introduced, and their piezoelectric properties and reliabilities are shown. Recent advances are introduced, and future development is discussed.

Potassium Sodium Niobate-Based Lead-Free Piezoelectric Multilayer Ceramics Co-Fired with Nickel Electrodes

PubMed Central

Kawada, Shinichiro; Hayashi, Hiroyuki; Ishii, Hideki; Kimura, Masahiko; Ando, Akira; Omiya, Suetake; Kubodera, Noriyuki

2015-01-01

Although lead-free piezoelectric ceramics have been extensively studied, many problems must still be overcome before they are suitable for practical use. One of the main problems is fabricating a multilayer structure, and one solution attracting growing interest is the use of lead-free multilayer piezoelectric ceramics. The paper reviews work that has been done by the authors on lead-free alkali niobate-based multilayer piezoelectric ceramics co-fired with nickel inner electrodes. Nickel inner electrodes have many advantages, such as high electromigration resistance, high interfacial strength with ceramics, and greater cost effectiveness than silver palladium inner electrodes. However, widely used lead zirconate titanate-based ceramics cannot be co-fired with nickel inner electrodes, and silver palladium inner electrodes are usually used for lead zirconate titanate-based piezoelectric ceramics. A possible alternative is lead-free ceramics co-fired with nickel inner electrodes. We have thus been developing lead-free alkali niobate-based multilayer ceramics co-fired with nickel inner electrodes. The normalized electric-field-induced thickness strain (Smax/Emax) of a representative alkali niobate-based multilayer ceramic structure with nickel inner electrodes was 360 pm/V, where Smax denotes the maximum strain and Emax denotes the maximum electric field. This value is about half that for the lead zirconate titanate-based ceramics that are widely used. However, a comparable value can be obtained by stacking more ceramic layers with smaller thicknesses. In the paper, the compositional design and process used to co-fire lead-free ceramics with nickel inner electrodes are introduced, and their piezoelectric properties and reliabilities are shown. Recent advances are introduced, and future development is discussed. PMID:28793646

COSAM program overview

NASA Technical Reports Server (NTRS)

Stephens, J. R.

1982-01-01

The COSAM program for reduction of the use of strategic alloying elements in nickel-based superalloys for gas turbine engines was reviewed. Sources, consumption, and pricing of cobalt, tantalum, columbium, and chromium are surveyed. Research projects in strategic element substitution, advanced processing concepts, and the development of alternate materials (intermetallics and iron-base alloys) are listed and research plans for FY 1983 and FY 1984 summarized.

Application of single crystal superalloys for Earth-to-orbit propulsion systems

NASA Technical Reports Server (NTRS)

Dreshfield, R. L.; Parr, R. A.

1987-01-01

Single crystal superalloys were first identified as potentially useful engineering materials for aircraft gas turbine engines in the mid-1960's. Although they were not introduced into service as turbine blades in commercial aircraft engines until the early 1980's, they have subsequently accumulated tens of millions of flight hours in revenue producing service. The space shuttle main engine (SSME) and potential advanced earth-to-orbit propulsion systems impose severe conditions on turbopump turbine blades which for some potential failure modes are more severe than in aircraft gas turbines. Research activities which are directed at evaluating the potential for single crystal superalloys for application as turbopump turbine blades in the SSME and advanced rocket engines are discussed. The mechanical properties of these alloys are summarized and the effects of hydrogen are noted. The use of high gradient directional solidification and hot isostatic pressing to improve fatigue properties is also addressed.

Orientation and temperature dependence of some mechanical properties of the single-crystal nickel-base superalloy Rene N4. 3: Tension-compression anisotropy

NASA Technical Reports Server (NTRS)

Miner, R. V.; Gaab, T. P.; Gayda, J.; Hemker, K. J.

1985-01-01

Single crystal superalloy specimens with various crystallographic directions along their axes were tested in compression at room temperature, 650, 760, 870, and 980 deg C. These results are compared with the tensile behavior studied previously. The alloy, Rene N4, was developed for gas turbine engine blades and has the nominal composition 3.7 Al, 4.2 Ti, 4 Ta, 0.5 Nb, 6 W, 1.5 Mo 9 Cr. 7.5 Co, balance Ni, in weight percent. Slip trace analysis showed that primary cube slip occurred even at room temperature for the 111 specimens. With increasing test temperature more orientations exhibited primary cube slip, until at 870 deg C only the 100 and 011 specimens exhibited normal octahedral slip. The yield strength for octahedral slip was numerically analysed using a model proposed by Lall, Chin, and Pope to explain deviations from Schmid's Law in the yielding behavior of a single phase Gamma prime alloy, Ni3(Al, Nb). The Schmid's Law deviations in Rene N4 were found to be largely due to a tension-compression anisotropy. A second effect, which increases trength for orientations away from 001, was found to be small in Rene N4. Analysis of recently published data on the single crystal superalloy PWA 1480 yielded the same result.

Flight Weight Design Nickel-Hydrogen Cells Using Lightweight Nickel Fiber Electrodes

NASA Technical Reports Server (NTRS)

Britton, Doris L.; Willis, Bob; Pickett, David F.

2003-01-01

The goal of this program is to develop a lightweight nickel electrode for advanced aerospace nickel-hydrogen cells and batteries with improved specific energy and specific volume. The lightweight nickel electrode will improve the specific energy of a nickel-hydrogen cell by >50%. These near-term advanced batteries will reduce power system mass and volume, while decreasing the cost, thus increasing mission capabilities and enabling small spacecraft missions. This development also offers a cost savings over the traditional sinter development methods for fabrication. The technology has been transferred to Eagle-Picher, a major aerospace battery manufacturer, who has scaled up the process developed at NASA GRC and fabricated electrodes for incorporation into flight-weight nickel-hydrogen cells.

Heat Treatment Devices and Method of Operation Thereof to Produce Dual Microstructure Superalloys Disks

NASA Technical Reports Server (NTRS)

Gayda, John (Inventor); Gabb, Timothy P. (Inventor); Kantzos, Peter T. (Inventor)

2003-01-01

A heat treatment assembly and heat treatment methods are disclosed for producing different microstructures in the bore and rim portions of nickel-based superalloy disks, particu- larly suited for gas turbine applications. The heat treatment assembly is capable of being removed from the furnace and disassembled to allow rapid fan or oil quenching of the disk. For solutioning heat treatments of the disk, temperatures higher than that of this solvus temperature of the disk are used to produce coarse grains in the rim of each disk so as to give maximum creep and dwell crack resistance at the rim service temperature. At the same time, solution temperature lower than the solvus temperature of the disk are provided to produce fine grain in the bore of the disk so as to give maximum strength and low cycle fatigue resistance.

Numerical Simulation of Transport Phenomena for a Double-Layer Laser Powder Deposition of Single-Crystal Superalloy

NASA Astrophysics Data System (ADS)

Liu, Zhaoyang; Qi, Huan

2014-04-01

A turbine blade made of single-crystal superalloys has been commonly used in gas turbine and aero engines. As an effective repair technology, laser powder deposition has been implemented to restore the worn turbine blade tips with a near-net shape capability and highly controllable solidified microstructure. Successful blade repair technology for single-crystal alloys requires a continuous epitaxial grain growth in the same direction of the crystalline orientation of the substrate material to the newly deposited layers. This work presents a three-dimensional numerical model to simulate the transport phenomena for a multilayer coaxial laser powder deposition process. Nickel-based single-crystal superalloy Rene N5 powder is deposited on a directional solidified substrate made of nickel-based directional-solidified alloy GTD 111 to verify the simulation results. The effects of processing parameters including laser power, scanning speed, and powder feeding rate on the resultant temperature field, fluid velocity field, molten pool geometric sizes, and the successive layer remelting ratios are studied. Numerical simulation results show that the maximum temperature of molten pool increases over layers due to the reduced heat dissipation capacity of the deposited geometry, which results in an increased molten pool size and fluid flow velocity at the successive deposited layer. The deposited bead geometry agrees well between the simulation and the experimental results. A large part of the first deposition layer, up to 85 pct of bead height, can be remelted during the deposition of the second layer. The increase of scanning speed decreases the ratio of G/ V (temperature gradient/solidification velocity), leading to an increased height ratio of the misoriented grain near the top surface of the previous deposited layer. It is shown that the processing parameters used in the simulation and experiment can produce a remelting ratio R larger than the misoriented grain height ratio

Mechanism of corrosion of Ni base superalloys by molten Na2MoO4 at elevated temperatures

NASA Technical Reports Server (NTRS)

Misra, A. K.; Stearns, C. A.

1983-01-01

The corrosion of nickel base superalloy, U-700, by molten Na2MoO4 was studied in the temperature range of 750 deg to 950 deg C. After an induction period, the rate of corrosion is linear and catastrophic corrosion is observed. It is shown that the induction period is associated with the attainment of a minimum MoO3 activity in the melt, which corresponds to the equilibrium MoO3 activity for the reaction, 2MoO3(l) + Mo = 3MoO2(s). A mechanism is proposed to describe the catastrophic nature of corrosion, which involves transport of Ni++ through the melt resulting in formulation of NiO at the melt gas interface and basic fluxing of Cr2O3. The effect of the amount of Na2MoO4 on the corrosion kinetics was also studied. It is found that evaporation and the thermodynamic calculations for the Na2MoO4 - MoO3 system the activity of MoO3 is reduced considerably when dissolved in Na2MoO4, which causes a sharp decrease in the rate of evaporation of MoO3 from a Na2MoO4 - MoO3 melt.

Barrier Coatings for Refractory Metals and Superalloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

SM Sabol; BT Randall; JD Edington

2006-02-23

In the closed working fluid loop of the proposed Prometheus space nuclear power plant (SNPP), there is the potential for reaction of core and plant structural materials with gas phase impurities and gas phase transport of interstitial elements between superalloy and refractory metal alloy components during service. Primary concerns are surface oxidation, interstitial embrittlement of refractory metals and decarburization of superalloys. In parallel with kinetic investigations, this letter evaluates the ability of potential coatings to prevent or impede communication between reactor and plant components. Key coating requirements are identified and current technology coating materials are reviewed relative to these requirements.more » Candidate coatings are identified for future evaluation based on current knowledge of design parameters and anticipated environment. Coatings were identified for superalloys and refractory metals to provide diffusion barriers to interstitial transport and act as reactive barriers to potential oxidation. Due to their high stability at low oxygen potential, alumina formers are most promising for oxidation protection given the anticipated coolant gas chemistry. A sublayer of iridium is recommended to provide inherent diffusion resistance to interstitials. Based on specific base metal selection, a thin film substrate--coating interdiffusion barrier layer may be necessary to meet mission life.« less

Effect of Process Variables on the Inertia Friction Welding of Superalloys LSHR and Mar-M247

NASA Astrophysics Data System (ADS)

Mahaffey, D. W.; Senkov, O. N.; Shivpuri, R.; Semiatin, S. L.

2016-08-01

The effect of inertia friction welding process parameters on microstructure evolution, weld plane quality, and the tensile behavior of welds between dissimilar nickel-base superalloys was established. For this purpose, the fine-grain, powder metallurgy alloy LSHR was joined to coarse-grain cast Mar-M247 using a fixed level of initial kinetic energy, but different combinations of the flywheel moment of inertia and initial rotation speed. It was found that welds made with the largest moment of inertia resulted in a sound bond with the best microstructure and room-temperature tensile strength equal to or greater than that of the parent materials. A relationship between the moment of inertia and weld process efficiency was established. The post-weld tensile behavior was interpreted in the context of observed microstructure gradients and weld-line defects.

The development of gamma-gamma-prime lamellar structures in a nickel-base superalloy during elevated temperature mechanical testing

NASA Technical Reports Server (NTRS)

Mackay, R. A.; Ebert, L. J.

1985-01-01

The kinetics of the formation and subsequent development of the directional coarsening of the gamma-prime precipitate in model Ni-Al-Mo-Ta superalloy single crystals are examined during tensile creep under various stress levels at 982 and 1038 C. Special attention is given to the gamma and gamma-prime relation to creep time and strain in order to trace the changing gamma-gamma-prime morphology. Directional coarsening of gamma-prime is found to begin during primary creep and its rate is shown to increase with an increase in temperature or stress level. The length of gamma-prime thickness increased linearly with time up to a plateau reached after the onset of steady state creep. The raft thickness, equal to the gamma-prime size, remained constant at this initial value up through the onset of the tertiary creep. The interlaminar spacing indicates the stability of directionally coarsened structure.

FIB–SEM tomography of 4th generation PWA 1497 superalloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ziętara, Maciej, E-mail: zietara@agh.edu.pl; Kruk, Adam, E-mail: kruczek@agh.edu.pl; Gruszczyński, Adam, E-mail: gruszcz@agh.edu.pl

2014-01-15

The effect of creep deformation on the microstructure of the PWA 1497 single crystal Ni-base superalloy developed for turbine blade applications was investigated. The aim of the present study was to characterize quantitatively a superalloy microstructure and subsequent development of rafted γ′ precipitates in the PWA 1497 during creep deformation at 982 °C and 248 MPa up to rupture. The PWA1497 microstructure was characterized by scanning electron microscopy and FIB–SEM electron tomography. The 3D reconstruction of the PWA1497 microstructure is presented and discussed. - Highlights: • The microstructure of PWA1497 superalloy was examined using FIB–SEM tomography. • In case ofmore » modern single crystal superalloys, measurements of A{sub A} are adequate for V{sub V}. • During creep the γ channel width increases from 65 to 193 nm for ruptured specimen. • Tomography is a useful technique for quantitative studies of material microstructure.« less

Solute partitioning in multi-component γ/γ' Co–Ni-base superalloys with near-zero lattice misfit

DOE Office of Scientific and Technical Information (OSTI.GOV)

Meher, S.; Carroll, L. J.; Pollock, T. M.

The addition of nickel to cobalt-base alloys enables alloys with a near zero γ – γ' lattice misfit. The solute partitioning between ordered γ' precipitates and the disordered γ matrix have been investigated using atom probe tomography. Lastly, the unique shift in solute partitioning in these alloys, as compared to that in simpler Co-base alloys, derives from changes in site substitution of solutes as the relative amounts of Co and Ni change, highlighting new opportunities for the development of advanced tailored alloys.

Solute partitioning in multi-component γ/γ' Co–Ni-base superalloys with near-zero lattice misfit

DOE PAGES

Meher, S.; Carroll, L. J.; Pollock, T. M.; ...

2015-11-21

The addition of nickel to cobalt-base alloys enables alloys with a near zero γ – γ' lattice misfit. The solute partitioning between ordered γ' precipitates and the disordered γ matrix have been investigated using atom probe tomography. Lastly, the unique shift in solute partitioning in these alloys, as compared to that in simpler Co-base alloys, derives from changes in site substitution of solutes as the relative amounts of Co and Ni change, highlighting new opportunities for the development of advanced tailored alloys.

Expert systems for superalloy studies

NASA Technical Reports Server (NTRS)

Workman, Gary L.; Kaukler, William F.

1990-01-01

There are many areas in science and engineering which require knowledge of an extremely complex foundation of experimental results in order to design methodologies for developing new materials or products. Superalloys are an area which fit well into this discussion in the sense that they are complex combinations of elements which exhibit certain characteristics. Obviously the use of superalloys in high performance, high temperature systems such as the Space Shuttle Main Engine is of interest to NASA. The superalloy manufacturing process is complex and the implementation of an expert system within the design process requires some thought as to how and where it should be implemented. A major motivation is to develop a methodology to assist metallurgists in the design of superalloy materials using current expert systems technology. Hydrogen embrittlement is disasterous to rocket engines and the heuristics can be very complex. Attacking this problem as one module in the overall design process represents a significant step forward. In order to describe the objectives of the first phase implementation, the expert system was designated Hydrogen Environment Embrittlement Expert System (HEEES).

Effect of rolling on the high temperature tensile and stress-rupture properties of tungsten fiber-superalloy composites

NASA Technical Reports Server (NTRS)

Petrasek, D. W.

1974-01-01

An investigation was conducted to determine the effects of mechanical working on the 1093 C (2000 F) tensile and stress-rupture strength of tungsten alloy/superalloy composites. Hot pressed composites containing either conventional tungsten lamp filament wire or tungsten-1% ThO2 wire and a nickel base alloy matrix were hot rolled at 1093 C (2000 F). The hot pressed and rolled composite specimens were then tested in tension and stress-rupture at 1093 C (2000 F). Rolling decreased the degree of fiber-matrix reaction as a function of time of exposure at 1093 C (2000 F). The stress-rupture properties of the rolled composites were superior to hot pressed composites containing equivalent diameter fibers. Rolling did not appreciably affect the 1093 C (2000 F) ultimate tensile strength of the composites.

The Effect of Stabilization Heat Treatments on the Tensile and Creep Behavior of an Advanced Nickel-Based Disk Alloy

NASA Technical Reports Server (NTRS)

Gayda, John

2003-01-01

As part of NASA s Advanced Subsonic Technology Program, a study of stabilization heat treatment options for an advanced nickel-base disk alloy, ME 209, was performed. Using a simple, physically based approach, the effect of stabilization heat treatments on tensile and creep properties was analyzed in this paper. Solutions temperature, solution cooling rate, and stabilization temperature/time were found to have a significant impact on tensile and creep properties. These effects were readily quantified using the following methodology. First, the effect of solution cooling rate was assessed to determine its impact on a given property. The as-cooled property was then modified by using two multiplicative factors which assess the impact of solution temperature and stabilization parameters. Comparison of experimental data with predicted values showed this physically based analysis produced good results that rivaled the statistical analysis employed, which required numerous changes in the form of the regression equation depending on the property and temperature in question. As this physically based analysis uses the data for input, it should be noted that predictions which attempt to extrapolate beyond the bounds of the data must be viewed with skepticism. Future work aimed at expanding the range of the stabilization/aging parameters explored in this study would be highly desirable, especially at the higher solution cooling rates.

Cooperative Materials Research Projects - Student Research Program III. Student Research Program to AFRL/RX: A Summary of Various Materials Research Projects

DTIC Science & Technology

2015-05-27

the material to make the microstructure the strongest for uses at high temperatures, specifically in the turbine of a jet engine. This specific set...useful for its applications. Works Cited Pollock, Tresa M., & Tin, Sammy. “Nickel-Based Superalloys for Advanced Turbine Engines: Chemistry...not insulated well enough though and there was dielectric breakdown of the insulation between the windings . This solenoid was rewrapped with two

Recent Advances in the Synthesis and Stabilization of Nickel and Nickel Oxide Nanoparticles: A Green Adeptness

PubMed Central

Rani, Aneela

2016-01-01

Green protocols for the synthesis of nanoparticles have been attracting a lot of attention because they are eco-friendly, rapid, and cost-effective. Nickel and nickel oxide nanoparticles have been synthesized by green routes and characterized for impact of green chemistry on the properties and biological effects of nanoparticles in the last five years. Green synthesis, properties, and applications of nickel and nickel oxide nanoparticles have been reported in the literature. This review summarizes the synthesis of nickel and nickel oxide nanoparticles using different biological systems. This review also provides comparative overview of influence of chemical synthesis and green synthesis on structural properties of nickel and nickel oxide nanoparticles and their biological behavior. It concludes that green methods for synthesis of nickel and nickel oxide nanoparticles are better than chemical synthetic methods. PMID:27413375

Soft computing methods in design of superalloys

NASA Technical Reports Server (NTRS)

Cios, K. J.; Berke, L.; Vary, A.; Sharma, S.

1995-01-01

Soft computing techniques of neural networks and genetic algorithms are used in the design of superalloys. The cyclic oxidation attack parameter K(sub a), generated from tests at NASA Lewis Research Center, is modeled as a function of the superalloy chemistry and test temperature using a neural network. This model is then used in conjunction with a genetic algorithm to obtain an optimized superalloy composition resulting in low K(sub a) values.

Soft Computing Methods in Design of Superalloys

NASA Technical Reports Server (NTRS)

Cios, K. J.; Berke, L.; Vary, A.; Sharma, S.

1996-01-01

Soft computing techniques of neural networks and genetic algorithms are used in the design of superalloys. The cyclic oxidation attack parameter K(sub a), generated from tests at NASA Lewis Research Center, is modelled as a function of the superalloy chemistry and test temperature using a neural network. This model is then used in conjunction with a genetic algorithm to obtain an optimized superalloy composition resulting in low K(sub a) values.

Orientation and faulted structure of γ'-phases in lanthanum-alloyed Ni-Al-Cr superalloy

NASA Astrophysics Data System (ADS)

Nikonenko, Elena; Shergaeva, Lyubov'; Popova, Natalya; Koneva, Nina; Qin, Rongshan; Gromov, Victor; Fedorischeva, Marina

2017-12-01

The paper presents the transmission and the scanning electron microscope investigations of thin foils of Ni-Al-Cr-based superalloy, which is obtained by the directional crystallization technique. This superalloy contains γ'- and γ- phases. Additionally, lanthanum is introduced in the superalloy in 0.015, 0.10 and 0.30 wt % concentrations. The superalloy specimens are then subjected to 1273 K annealing during 10 and 25 h. It is shown that γ'-phase is major. In the superalloy, lanthanides La2Ni3 and Al2La are detected along with carbide La2C3 particles located on dislocations of the major phase. The amount of phases in the superalloy depends on its thermal treatment and lanthanum concentration. The investigations include the effect of annealing on scalar density of dislocations in γ'-phase. It is demonstrated that lanthanum alloying modifies the preferred orientation of γ'-phase. Annealing of lanthanum-alloyed superalloy causes the orientation dispersion. In γ'-phase, the correlation is observed between the degree of heterogeneity of solid solution and scalar dislocation density. It is shown that this heterogeneity results in the formation of high-density dislocations in γ'- phase.

Slip Analysis in a Ni-base Superalloy

NASA Technical Reports Server (NTRS)

Westbrooke, Eboni F.; Forero, Luis E.; Ebrahimi, Fereshteh

2004-01-01

A Ni-base superalloy single crystal with Gamma/Gamma' structure was tested at room temperature along the , <110> and <111> directions. Consistent with previously reported investigations, this alloy did not obey the Schmid law and the CRSS (critical resolved shear stress) was noticeably lower for the <111>-oriented samples. Furthermore, the strain hardening rate decreased and the degree of deformation localization increased in the order of <111>, and <110> orientations. The appearance and orientation of deformation traces were found to depend on the loading orientation as well as the amount of strain. In general, when Gamma'-particles were sheared, the traces followed the expected octahedral shear planes. It is demonstrated that the wavy deformation traces that do not follow the {111} planes are associated with changes in the gamma-channels width and the falling off of the gamma-particles. In this paper the evolution of deformation bands are discussed in terms of plastic localization at microscopic, mesoscopic and macroscopic levels.

Cobalt: A vital element in the aircraft engine industry

NASA Technical Reports Server (NTRS)

Stephens, J. R.

1981-01-01

Recent trends in the United States consumption of cobalt indicate that superalloys for aircraft engine manufacture require increasing amounts of this strategic element. Superalloys consume a lion's share of total U.S. cobalt usage which was about 16 million pounds in 1980. In excess of 90 percent of the cobalt used in this country was imported, principally from the African countries of Zaire and Zambia. Early studies on the roles of cobalt as an alloying element in high temperature alloys concentrated on the simple Ni-Cr and Nimonic alloy series. The role of cobalt in current complex nickel base superalloys is not well defined and indeed, the need for the high concentration of cobalt in widely used nickel base superalloys is not firmly established. The current cobalt situation is reviewed as it applies to superalloys and the opportunities for research to reduce the consumption of cobalt in the aircraft engine industry are described.

Nickel-based anodic electrocatalysts for fuel cells and water splitting

NASA Astrophysics Data System (ADS)

Chen, Dayi

Our world is facing an energy crisis, so people are trying to harvest and utilize energy more efficiently. One of the promising ways to harvest energy is via solar water splitting to convert solar energy to chemical energy stored in hydrogen. Another of the options to utilize energy more efficiently is to use fuel cells as power sources instead of combustion engines. Catalysts are needed to reduce the energy barriers of the reactions happening at the electrode surfaces of the water-splitting cells and fuel cells. Nickel-based catalysts happen to be important nonprecious electrocatalysts for both of the anodic reactions in alkaline media. In alcohol fuel cells, nickel-based catalysts catalyze alcohol oxidation. In water splitting cells, they catalyze water oxidation, i.e., oxygen evolution. The two reactions occur in a similar potential range when catalyzed by nickel-based catalysts. Higher output current density, lower oxidation potential, and complete substrate oxidation are preferred for the anode in the applications. In this dissertation, the catalytic properties of nickel-based electrocatalysts in alkaline medium for fuel oxidation and oxygen evolution are explored. By changing the nickel precursor solubility, nickel complex nanoparticles with tunable sizes on electrode surfaces were synthesized. Higher methanol oxidation current density is achieved with smaller nickel complex nanoparticles. DNA aggregates were used as a polymer scaffold to load nickel ion centers and thus can oxidize methanol completely at a potential about 0.1 V lower than simple nickel electrodes, and the methanol oxidation pathway is changed. Nickel-based catalysts also have electrocatalytic activity towards a wide range of substrates. Experiments show that methanol, ethanol, glycerol and glucose can be deeply oxidized and carbon-carbon bonds can be broken during the oxidation. However, when comparing methanol oxidation reaction to oxygen evolution reaction catalyzed by current nickel-based

High energy density micro-fiber based nickel electrode for aerospace batteries

NASA Technical Reports Server (NTRS)

Francisco, Jennifer; Chiappetti, Dennis; Coates, Dwaine

1996-01-01

The nickel electrode is the specific energy limiting component in battery systems such as nickel-hydrogen, nickel-metal hydride and nickel-zinc. Lightweight, high energy density nickel electrodes have been developed which deliver in excess of 180 mAh/g at the one-hour discharge rate. These electrodes are based on a highly porous, nickel micro-fiber (less than 10 micron diameter) substrate, electrochemically impregnated with nickel-hydroxide active material. Electrodes are being tested both as a flooded half-cell and in full nickel-hydrogen and nickel-metal hydride cells. The electrode technology developed is applicable to commercial nickel-based batteries for applications such as electric vehicles, cellular telephones and laptop computers and for low-cost, high energy density military and aerospace applications.

Anisotropy of nickel-base superalloy single crystals

NASA Technical Reports Server (NTRS)

Mackay, R. A.; Dreshfield, R. L.; Maier, R. D.

1980-01-01

The influence of orientation on the tensile and stress rupture behavior of 52 Mar-M247 single crystals was studied. Tensile tests were performed at temperatures between 23 and 1093 C; stress rupture behavior was examined between 760 and 1038 C. The mechanical behavior of the single crystals was rationalized on the basis of the Schmid factor contours for the operative slip systems and the lattice rotations which the crystals underwent during deformation. The tensile properties correlated well with the appropriate Schmid factor contours. The stress rupture lives at lower testing temperatures were greatly influenced by the lattice rotations required to produce cross slip. A unified analysis was attained for the stress rupture life data generated for the Mar-M247 single crystals at 760 and 774 C under a stress of 724 MPa and the data reported for Mar-M200 single crystals tested at 760 C under a stress of 689 MPa. Based on this analysis, the stereographic triangle was divided into several regions which were rank ordered according to stress rupture life for this temperature regime.

Fatigue properties of MA 6000E, a gamma-prime strengthened ODS alloy. [Oxide Dispersion Strengthened Ni-base alloy for gas turbine blade applications

NASA Technical Reports Server (NTRS)

Kim, Y. G.; Merrick, H. F.

1980-01-01

MA 6000E is a corrosion resistant, gamma-prime strengthened ODS alloy under development for advanced turbine blade applications. The high temperature, 1093 C, rupture strength is superior to conventional nickel-base alloys. This paper addresses the fatigue behavior of the alloy. Excellent properties are exhibited in low and high cycle fatigue and also thermal fatigue. This is attributed to a unique combination of microstructural features, i.e., a fine distribution of dispersed oxides and other nonmetallics, and the highly elongated grain structure which advantageously modify the deformation characteristics and crack initiation and propagation modes from that characteristic of conventional gamma-prime hardened superalloys.

Effects of Long Term Exposures on PM Disk Superalloys

NASA Technical Reports Server (NTRS)

Gabb, T. P.; Sudbrack, C. K.; Draper, S. L.; MacKay, R. A.; Telesman, J.

2013-01-01

Turbine disks in some advanced engine applications may be exposed to temperatures above 700 C for extended periods of time, approaching 1,000 h. These exposures could affect the near-surface composition and microstructure through formation of damaged and often embrittled layers. The creation of such damaged layers could significantly affect local mechanical properties. Powder metal disk superalloys LSHR and ME3 were exposed at temperatures of 704, 760, and 815 C for times up to 2,020 h, and the types and depths of environmental attacked were measured. Fatigue tests were performed for selected cases at 704 and 760 C, to determine the impact of these exposures on fatigue life. Fatigue resistance was reduced up to 98% in both superalloys for some exposure conditions. Tensile tests were also performed to help understand fatigue responses, and showed corresponding reductions in ductility. The changes in surface composition and phases, depths of these changed layers, failure responses, and failure initiation modes were compared.

Literature survey on oxidations and fatigue lives at elevated temperatures

NASA Technical Reports Server (NTRS)

Liu, H. W.; Oshida, Y.

1984-01-01

Nickel-base superalloys are the most complex and the most widely used for high temperature applications such as aircraft engine components. The desirable properties of nickel-base superalloys at high temperatures are tensile strength, thermomechanical fatigue resistance, low thermal expansion, as well as oxidation resistance. At elevated temperature, fatigue cracks are often initiated by grain boundary oxidation, and fatigue cracks often propagate along grain boundaries, where the oxidation rate is higher. Oxidation takes place at the interface between metal and gas. Properties of the metal substrate, the gaseous environment, as well as the oxides formed all interact to make the oxidation behavior of nickel-base superalloys extremely complicated. The important topics include general oxidation, selective oxidation, internal oxidation, grain boundary oxidation, multilayer oxide structure, accelerated oxidation under stress, stress-generation during oxidation, composition and substrate microstructural changes due to prolonged oxidation, fatigue crack initiation at oxidized grain boundaries and the oxidation accelerated fatigue crack propagation along grain boundaries.

Formation of β-NiAl Phase During Casting of a Ni-Based Superalloy

NASA Astrophysics Data System (ADS)

Detrois, Martin; Jablonski, Paul D.

2018-04-01

A high-refractory Ni-based superalloy prototype was melted on a research scale while simulating industry practices. Ingots were vacuum induction melted and subjected to a computationally optimized homogenization heat treatment prior to fabrication which consisted of forging and hot rolling. Failure of one of the ingots at the early stage of the forging process was attributed to the precipitation of the β-NiAl phase during melting which stabilized the eutectic constituent.

Validation test of 125 Ah advanced design IPV nickel-hydrogen flight cells

NASA Technical Reports Server (NTRS)

Smithrick, John J.; Hall, Stephen W.

1993-01-01

An update of validation test results confirming the advanced design nickel-hydrogen cell is presented. An advanced 125 Ah individual pressure vessel Ni-H cell was designed. The primary function of the advanced cell is to store and deliver energy for long-term LEO spacecraft missions. The new features of this design are: (1) use of 26 percent rather than 31 percent KOH electrolyte; (2) use of a patented catalyzed wall wick; (3) use of serrated-edge separators to facilitate gaseous O and H flow within the cell, while maintaining physical contact with the wall wick for electrolyte management; and (4) use of a floating rather than a fixed stack to accommodate Ni electrode expansion due to charge/discharge cycling. The significant improvements resulting from these innovations are extended cycle life; enhanced thermal, electrolyte, and oxygen management; and accommodation of Ni electrode expansion. Six 125 Ah flight cells based on this design were fabricated; the catalyzed wall wick cells have been cycled for over 19,000 cycles with no cell failures in the continuing test. Two of the noncatalyzed wall wick cells failed (cycles 9588 and 13,900).

Advanced single crystal for SSME turbopumps

NASA Technical Reports Server (NTRS)

Fritzemeier, L. G.

1989-01-01

The objective of this program was to evaluate the influence of high thermal gradient casting, hot isostatic pressing (HIP) and alternate heat treatments on the microstructure and mechanical properties of a single crystal nickel base superalloy. The alloy chosen for the study was PWA 1480, a well characterized, commercial alloy which had previously been chosen as a candidate for the Space Shuttle Main Engine high pressure turbopump turbine blades. Microstructural characterization evaluated the influence of casting thermal gradient on dendrite arm spacing, casting porosity distribution and alloy homogeneity. Hot isostatic pressing was evaluated as a means of eliminating porosity as a preferred fatigue crack initiation site. The alternate heat treatment was chosen to improve hydrogen environment embrittlement resistance and for potential fatigue life improvement. Mechanical property evaluation was aimed primarily at determining improvements in low cycle and high cycle fatigue life due to the advanced processing methods. Statistically significant numbers of tests were conducted to quantitatively demonstrate life differences. High thermal gradient casting improves as-cast homogeneity, which facilitates solution heat treatment of PWA 1480 and provides a decrease in internal pore size, leading to increases in low cycle and high cycle fatigue lives.

The Compositional Dependence of the Microstructure and Properties of CMSX-4 Superalloys

NASA Astrophysics Data System (ADS)

Yu, Hao; Xu, Wei; Van Der Zwaag, Sybrand

2018-01-01

The degradation of creep resistance in Ni-based single-crystal superalloys is essentially ascribed to their microstructural evolution. Yet there is a lack of work that manages to predict (even qualitatively) the effect of alloying element concentrations on the rate of microstructural degradation. In this research, a computational model is presented to connect the rafting kinetics of Ni superalloys to their chemical composition by combining thermodynamics calculation and a modified microstructural model. To simulate the evolution of key microstructural parameters during creep, the isotropic coarsening rate and γ/ γ' misfit stress are defined as composition-related parameters, and the effect of service temperature, time, and applied stress are taken into consideration. Two commercial superalloys, for which the kinetics of the rafting process are selected as the reference alloys, and the corresponding microstructural parameters are simulated and compared with experimental observations reported in the literature. The results confirm that our physical model not requiring any fitting parameters manages to predict (semiquantitatively) the microstructural parameters for different service conditions, as well as the effects of alloying element concentrations. The model can contribute to the computational design of new Ni-based superalloys.

High-temperature oxidation/corrosion of iron-based superalloys

NASA Technical Reports Server (NTRS)

Lemkey, F. D.; Smeggil, J. G.; Bailey, R. S.; Schuster, J. C.; Nowotny, H.

1987-01-01

The oxidation and sulfidation of several novel iron-base superalloys were evaluated in high-temperature cyclic tests. The experimental austenitic alloys examined were modifications of NASAUT-4GA which were developed for Stirling-engine application. The weight gains and resulting surface scales were measured and analyzed. Mixed oxide scales were found to form on all specimens exposed above 871 C. The build-up of these scales led to a depletion of Mn and Cr in a zone adjacent to the oxides. In addition, the initial oxidation of the Fe-rich alloy was inhibited by a thin but tenacious Si layer which formed at the interface between oxides and the parent layer. Sulfidation tests using Na2SO4 coatings resulted in the formation of a protective spinel and alpha-Fe2O3 phases. Preferential attack of the carbide phase by hydrogen was not observed after 350 h at 871 C.

The Effect of Forging Variables on the Supersolvus Heat-Treatment Response of Powder-Metallurgy Nickel-Base Superalloys

NASA Astrophysics Data System (ADS)

Semiatin, S. L.; Shank, J. M.; Shiveley, A. R.; Saurber, W. M.; Gaussa, E. F.; Pilchak, A. L.

2014-12-01

The effect of subsolvus forging temperature and strain rate on the grain size developed during final supersolvus heat treatment (SSHT) of two powder-metallurgy, gamma-gamma prime superalloys, IN-100 and LSHR, was established. For this purpose, isothermal, hot compression tests were performed at temperatures ranging from 1144 K (871 °C) and 22 K (22 °C) below the respective gamma-prime solvus temperatures ( T γ') and strain rates between 0.0003 and 10 s-1. Deformed samples were then heat treated 20 K (20 °C) above the solvus for 1 h with selected additional samples exposed for shorter and longer times. For both alloys, the grain size developed during SSHT was in the range of 15 to 30 μm, except for those processing conditions consisting of pre-deformation at the highest temperature, i.e., T γ'—22 K ( T γ'—22 °C), and strain rates in the range of ~0.001 to 0.1 s-1. In these latter instances, the heat-treated grain size was approx. four times as large. The observations were interpreted in terms of the mechanisms of deformation during hot working and their effect on the driving forces for grain-boundary migration which controls the evolution of the gamma-grain size.

Enhancing the Oxidation Performance of Wrought Ni-Base Superalloy by Minor Additions of Active Elements

NASA Astrophysics Data System (ADS)

Tawancy, H. M.

2016-12-01

We show that the oxidation performance of Cr2O3-forming superalloy based upon the Ni-Cr-W system is significantly improved by the presence of minor concentrations of La, Si and Mn, which outweigh the detrimental effect of high W concentration in the alloy. Although Cr2O3 is known to transform into volatile CrO3 at temperatures ≥950 °C, the respective protection is extended to temperatures reaching 1150 °C, which has also been correlated with the beneficial effects of La, Si and Mn. During high-temperature oxidation, an inner protective La- and Si-modified layer of α-Cr2O3 in contact with the superalloy substrate is developed and shielded by an outermost layer of MnCr2O4. The distribution of La and Si in the inner oxide layer has been characterized down to the scale of transmission electron microscopy, and the possible mechanisms underlying their beneficial effects are elucidated.

Very High Cycle Fatigue of Ni-Based Single-Crystal Superalloys at High Temperature

NASA Astrophysics Data System (ADS)

Cervellon, A.; Cormier, J.; Mauget, F.; Hervier, Z.; Nadot, Y.

2018-05-01

Very high cycle fatigue (VHCF) properties at high temperature of Ni-based single-crystal (SX) superalloys and of a directionally solidified (DS) superalloy have been investigated at 20 kHz and a temperature of 1000 °C. Under fully reversed conditions (R = - 1), no noticeable difference in VHCF lifetimes between all investigated alloys has been observed. Internal casting pores size is the main VHCF lifetime-controlling factor whatever the chemical composition of the alloys. Other types of microstructural defects (eutectics, carbides), if present, may act as stress concentration sites when the number of cycles exceed 109 cycles or when porosity is absent by applying a prior hot isostatic pressing treatment. For longer tests (> 30 hours), oxidation also controls the main crack initiation sites leading to a mode I crack initiation from oxidized layer. Under such conditions, alloy's resistance to oxidation has a prominent role in controlling the VHCF. When creep damage is present at high ratios (R ≥ 0.8), creep resistance of SX/DS alloys governs VHCF lifetime. Under such high mean stress conditions, SX alloys developed to retard the initiation and creep propagation of mode I micro-cracks from pores have better VHCF lifetimes.

Anisotropic constitutive model for nickel base single crystal alloys: Development and finite element implementation

NASA Technical Reports Server (NTRS)

Dame, L. T.; Stouffer, D. C.

1986-01-01

A tool for the mechanical analysis of nickel base single crystal superalloys, specifically Rene N4, used in gas turbine engine components is developed. This is achieved by a rate dependent anisotropic constitutive model implemented in a nonlinear three dimensional finite element code. The constitutive model is developed from metallurigical concepts utilizing a crystallographic approach. A non Schmid's law formulation is used to model the tension/compression asymmetry and orientation dependence in octahedral slip. Schmid's law is a good approximation to the inelastic response of the material in cube slip. The constitutive equations model the tensile behavior, creep response, and strain rate sensitivity of these alloys. Methods for deriving the material constants from standard tests are presented. The finite element implementation utilizes an initial strain method and twenty noded isoparametric solid elements. The ability to model piecewise linear load histories is included in the finite element code. The constitutive equations are accurately and economically integrated using a second order Adams-Moulton predictor-corrector method with a dynamic time incrementing procedure. Computed results from the finite element code are compared with experimental data for tensile, creep and cyclic tests at 760 deg C. The strain rate sensitivity and stress relaxation capabilities of the model are evaluated.

A study of the microstructure of a rapidly solidified nickel-base superalloy modified with boron. M.S. Thesis. Final Contractor Report

NASA Technical Reports Server (NTRS)

Speck, J. S.

1986-01-01

The microstructures of melt-spun superalloy ribbons with variable boron levels have been studied by transmission electron microscopy. The base alloy was of approximate composition Ni-11% Cr-5%Mo-5%Al-4%Ti with boron levels of 0.06, 0.12, and 0.60 percent (all by weight). Thirty micron thick ribbons display an equiaxed chill zone near the wheel contact side which develops into primary dendrite arms in the ribbon center. Secondary dendrite arms are observed near the ribbon free surface. In the higher boron bearing alloys, boride precipitates are observed along grain boundaries. A concerted effort has been made to elucidate true grain shapes by the use of bright field/dark field microscopy. In the low boron alloy, grain shapes are often convex, and grain faces are flat. Boundary faces frequently have large curvature, and grain shapes form concave polygons in the higher boron level alloys. It is proposed that just after solidification, in all of the alloys studied, grain shapes were initially concave and boundaries were wavy. Boundary straightening is presumed to occur on cooling in the low boron alloy. Boundary migration is precluded in the higher boron alloys by fast precipitation of borides at internal interfaces.

Feasibility Study for Casting of High Temperature Refractory Superalloy Composites

NASA Technical Reports Server (NTRS)

Lee, Jonathan A.

1998-01-01

Abstract This study investigated the feasibility of using conventional casting technique to fabricate refractory wires reinforced superalloy composites. These composites were being developed for advanced rocket engine turbine blades and other high temperature applications operating up to 2000 F. Several types of refractory metal wires such as W- Th, W-Re, Mo-Hf-C and W-HF-C reinforced waspaloy were experimentally cast and heat treated at 2000 F up to 48 hrs. Scanning electron microscope analysis was conducted in regions adjacent to the wire-matrix interface to determine the reaction zone and chemical compatibility resulting from material interdiffusion. It was concluded that fabrication using conventional casting may be feasible because the wire-matrix reaction zone thickness was comparable to similar composites produced by arc-sprayed monotape with hot isostatic pressing technique, Moreover, it was also found that the chemical compatibility could be improved significantly through a slight modification of the superalloy matrix compositions.

Advanced nickel-metal hydride cell development at Hughes: A joint work with US government

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lim, H.S.; Pickett, D.F.; Stockel, J.F.

1995-01-25

Hughes is currently engaged in the development of an advanced nickel-metal hydride (Ni/MHx) cell for spacecraft application with performance goals of 15 years of opertion in a geosynchronous earth orbit at 80% depth of discharge and over 30,000 cycles of life at 30% depth of discharge in a typical low earth orbit. We have developed the basic fabrication technique for a lightweight and potentially long life nickel electrode which is useable in space Ni/MHx cells. We have developed several attractive hydride alloys which are useable in hydride electrodes and basic fabrication techniques for lightweight, inexpensive, and potentially long life hydridemore » electrodes for a Ni/MHx cell. Utilizing Hughes extensive experiences in development of advanced Ni/Cd and Ni/H{sub 2} cells, we plan to develop a first generation space Ni/MHx cell design by 1995 and have the cell flight ready by 1997.« less

Advanced nickel-metal hydride cell development at Hughes: A joint work with US government

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lim, H.S.; Pickett, D.F.; Stockel, J.F.

1995-07-01

Hughes is currently engaged in the development of an advanced nickel-metal hydride (Ni/MHx) cell for spacecraft application with performance goals of 15 years of operation in a geosynchronous earth orbit at 805 depth of discharge and over 30,000 cycles of life at 30% depth of discharge in a typical low earth orbit. The authors have developed the basic fabrication technique for a lightweight and potentially long life nickel electrode which is usable in space Ni/MHx cells. The authors have developed several attractive hydride alloys which are usable in hydride electrodes and basic fabrication techniques for lightweight, inexpensive, and potentially longmore » life hydride electrodes for a Ni/MHx cell. Utilizing Hughes extensive experiences in development of advanced Ni/Cd and Ni/H{sub 2} cells, the authors plan to develop a first generation space Ni/MHx cell design by 1995 and have the cell flight ready by 1997.« less

Forging Oxide-Dispersion-Strengthened Superalloys

NASA Technical Reports Server (NTRS)

Harf, F. H.; Glasgow, T. K.; Moracz, D. J.; Austin, C. M.

1986-01-01

Cladding of mild steel prevents surface cracking when alloy contacts die. Continual need for improvements in properties of alloys capable of withstanding elevated temperatures. Accomplished by using oxide-dispersion-strengthed superalloys such as Inconel Alloy MA 6000. Elevated tensile properties of forged alloy equal those of hot-rolled MA 6000 bar. Stress-rupture properties somewhat lower than those of bar stock but, at 1,100 degrees C, exceed those of strongest commercial single crystal, directionally solidified and conventionally cast superalloys.

Aircraft gas turbine materials and processes.

PubMed

Kear, B H; Thompson, E R

1980-05-23

Materials and processing innovations that have been incorporated into the manufacture of critical components for high-performance aircraft gas turbine engines are described. The materials of interest are the nickel- and cobalt-base superalloys for turbine and burner sections of the engine, and titanium alloys and composites for compressor and fan sections of the engine. Advanced processing methods considered include directional solidification, hot isostatic pressing, superplastic foring, directional recrystallization, and diffusion brazing. Future trends in gas turbine technology are discussed in terms of materials availability, substitution, and further advances in air-cooled hardware.

APS TBC performance on directionally-solidified superalloy substrates with HVOF NiCoCrAlYHfSi bond coatings

DOE PAGES

Lance, Michael J.; Unocic, Kinga A.; Haynes, James A.; ...

2015-09-04

Directionally-solidified (DS) superalloy components with advanced thermal barrier coatings (TBC) to lower the metal operating temperature have the potential to replace more expensive single crystal superalloys for large land-based turbines. In order to assess relative TBC performance, furnace cyclic testing was used with superalloys 1483, X4 and Hf-rich DS 247 substrates and high velocity oxygen fuel (HVOF)-NiCoCrAlYHfSi bond coatings at 1100 °C with 1-h cycles in air with 10% H 2O. With these coating and test conditions, there was no statistically-significant effect of substrate alloy on the average lifetime of the air plasma sprayed (APS) yttria-stabilized zirconia (YSZ) top coatingsmore » on small coupons. Using photo-stimulated luminescence piezospectroscopy maps at regular cycling intervals, the residual compressive stress in the α-Al 2O 3 scale underneath the YSZ top coating and on a bare bond coating was similar for all three substrates and delaminations occurred at roughly the same rate and frequency. As a result, x-ray fluorescence (XRF) measurements collected from the bare bond coating surface revealed higher Ti interdiffusion occurring with the 1483 substrate, which contained the highest Ti content.« less

A statistical analysis of elevated temperature gravimetric cyclic oxidation data of 36 Ni- and Co-base superalloys based on an oxidation attack parameter

NASA Technical Reports Server (NTRS)

Barrett, Charles A.

1992-01-01

A large body of high temperature cyclic oxidation data generated from tests at NASA Lewis Research Center involving gravimetric/time values for 36 Ni- and Co-base superalloys was reduced to a single attack parameter, K(sub a), for each run. This K(sub a) value was used to rank the cyclic oxidation resistance of each alloy at 1000, 1100, and 1150 C. These K(sub a) values were also used to derive an estimating equation using multiple linear regression involving log(sub 10)K(sub a) as a function of alloy chemistry and test temperature. This estimating equation has a high degree of fit and could be used to predict cyclic oxidation behavior for similar alloys and to design an optimum high strength Ni-base superalloy with maximum high temperature cyclic oxidation resistance. The critical alloy elements found to be beneficial were Al, Cr, and Ta.

Joint Development of a Fourth Generation Single Crystal Superalloy

NASA Technical Reports Server (NTRS)

Walston, S.; Cetel, A.; MacKay, R.; OHara, K.; Duhl, D.; Dreshfield, R.

2004-01-01

A new, fourth generation, single crystal superalloy has been jointly developed by GE Aircraft Engines, Pratt & Whitney, and NASA. The focus of the effort was to develop a turbine airfoil alloy with long-term durability for use in the High Speed Civil Transport. In order to achieve adequate long-time strength improvements at moderate temperatures and retain good microstructural stability, it was necessary to make significant composition changes from 2nd and 3rd generation single crystal superalloys. These included lower chromium levels, higher cobalt and rhenium levels and the inclusion of a new alloying element, ruthenium. It was found that higher Co levels were beneficial to reducing both TCP precipitation and SRZ formation. Ruthenium caused the refractory elements to partition more strongly to the ' phase, which resulted in better overall alloy stability. The final alloy, EPM 102, had significant creep rupture and fatigue improvements over the baseline production alloys and had acceptable microstructural stability. The alloy is currently being engine tested and evaluated for advanced engine applications.

Interdiffusion behavior between NiAlHf coating and Ni-based single crystal superalloy with different crystal orientations

NASA Astrophysics Data System (ADS)

Wang, Ruili; Gong, Xueyuan; Peng, Hui; Ma, Yue; Guo, Hongbo

2015-01-01

NiAlHf coatings were deposited onto Ni-based single crystal (SC) superalloy with different crystal orientations by electron beam physical vapor deposition (EB-PVD). The effects of the crystal orientations of the superalloy substrate on inter-diffusion behavior between the substrate and the NiAlHf coating were investigated. Substrate diffusion zone (SDZ) containing needle-like μ phases and interdiffusion zone (IDZ) mainly consisting of the ellipsoidal and rod-like μ phases were formed in the SC alloy after heat-treatment 10 h at 1100 °C. The thickness of secondary reaction zone (SRZ) formed in the SC alloy with (0 1 1) crystal orientation is about 14 μm after 50 h heat-treatment at 1100 °C, which is relatively thicker than that in the SC alloy with (0 0 1) crystal orientation, whereas the IDZ revealed similar thickness.

Molecular dynamics study on the evolution of interfacial dislocation network and mechanical properties of Ni-based single crystal superalloys

NASA Astrophysics Data System (ADS)

Li, Nan-Lin; Wu, Wen-Ping; Nie, Kai

2018-05-01

The evolution of misfit dislocation network at γ /γ‧ phase interface and tensile mechanical properties of Ni-based single crystal superalloys at various temperatures and strain rates are studied by using molecular dynamics (MD) simulations. From the simulations, it is found that with the increase of loading, the dislocation network effectively inhibits dislocations emitted in the γ matrix cutting into the γ‧ phase and absorbs the matrix dislocations to strengthen itself which increases the stability of structure. Under the influence of the temperature, the initial mosaic structure of dislocation network gradually becomes irregular, and the initial misfit stress and the elastic modulus slowly decline as temperature increasing. On the other hand, with the increase of the strain rate, it almost has no effect on the elastic modulus and the way of evolution of dislocation network, but contributes to the increases of the yield stress and tensile strength. Moreover, tension-compression asymmetry of Ni-based single crystal superalloys is also presented based on MD simulations.

Nondestructive Evaluation Approaches Developed for Material Characterization in Aeronautics and Space Applications

NASA Technical Reports Server (NTRS)

Baaklini, George Y.; Kautz, Harold E.; Gyekenyesi, Andrew L.; Abdul-Aziz, Ali; Martin, Richard E.

2001-01-01

At the NASA Glenn Research Center, nondestructive evaluation (NDE) approaches were developed or tailored for characterizing advanced material systems. The emphasis was on high-temperature aerospace propulsion applications. The material systems included monolithic ceramics, superalloys, and high-temperature composites. In the aeronautics area, the major applications were cooled ceramic plate structures for turbine applications, gamma-TiAl blade materials for low-pressure turbines, thermoelastic stress analysis for residual stress measurements in titanium-based and nickel-based engine materials, and acousto-ultrasonics for creep damage assessment in nickel-based alloys. In the space area, applications consisted of cooled carbon-carbon composites for gas generator combustors and flywheel rotors composed of carbon-fiber-reinforced polymer matrix composites for energy storage on the International Space Station.

Materials for Advanced Turbine Engines. Volume 1; Power Metallurgy Rene 95 Rotating Turbine Engine Parts

NASA Technical Reports Server (NTRS)

Pfouts, W. R.; Shamblen, C. E.; Mosier, J. S.; Peebles, R. E.; Gorsler, R. W.

1979-01-01

An attempt was made to improve methods for producing powder metallurgy aircraft gas turbine engine parts from the nickel base superalloy known as Rene 95. The parts produced were the high pressure turbine aft shaft for the CF6-50 engine and the stages 5 through 9 compressor disk forgings for the CFM56/F101 engines. A 50% cost reduction was achieved as compared to conventional cast and wrought processing practices. An integrated effort involving several powder producers and a major forging source were included.

Multiscale modelling and experimentation of hydrogen embrittlement in aerospace materials

NASA Astrophysics Data System (ADS)

Jothi, Sathiskumar

Pulse plated nickel and nickel based superalloys have been used extensively in the Ariane 5 space launcher engines. Large structural Ariane 5 space launcher engine components such as combustion chambers with complex microstructures have usually been manufactured using electrodeposited nickel with advanced pulse plating techniques with smaller parts made of nickel based superalloys joined or welded to the structure to fabricate Ariane 5 space launcher engines. One of the major challenges in manufacturing these space launcher components using newly developed materials is a fundamental understanding of how different materials and microstructures react with hydrogen during welding which can lead to hydrogen induced cracking. The main objective of this research has been to examine and interpret the effects of microstructure on hydrogen diffusion and hydrogen embrittlement in (i) nickel based superalloy 718, (ii) established and (iii) newly developed grades of pulse plated nickel used in the Ariane 5 space launcher engine combustion chamber. Also, the effect of microstructures on hydrogen induced hot and cold cracking and weldability of three different grades of pulse plated nickel were investigated. Multiscale modelling and experimental methods have been used throughout. The effect of microstructure on hydrogen embrittlement was explored using an original multiscale numerical model (exploiting synthetic and real microstructures) and a wide range of material characterization techniques including scanning electron microscopy, 2D and 3D electron back scattering diffraction, in-situ and ex-situ hydrogen charged slow strain rate tests, thermal spectroscopy analysis and the Varestraint weldability test. This research shows that combined multiscale modelling and experimentation is required for a fundamental understanding of microstructural effects in hydrogen embrittlement in these materials. Methods to control the susceptibility to hydrogen induced hot and cold cracking and

76 FR 8773 - Superalloy Degassed Chromium From Japan

Federal Register 2010, 2011, 2012, 2013, 2014

2011-02-15

... INTERNATIONAL TRADE COMMISSION [Investigation No. 731-TA-1090 (Review)] Superalloy Degassed Chromium From Japan AGENCY: United States International Trade Commission. ACTION: Termination of five-year... revocation of the antidumping duty order on superalloy degassed chromium from Japan would be likely to lead...

The Mechanical Properties of Candidate Superalloys for a Hybrid Turbine Disk

NASA Technical Reports Server (NTRS)

Gabb, Timothy P.; MacKay, Rebecca A.; Draper, Susan L.; Sudbrack, Chantal K.; Nathal, Michael V.

2013-01-01

The mechanical properties of several cast blade superalloys and one powder metallurgy disk superalloy were assessed for potential use in a dual alloy hybrid disk concept of joined dissimilar bore and web materials. Grain size was varied for each superalloy class. Tensile, creep, fatigue, and notch fatigue tests were performed at 704 to 815 degC. Typical microstructures and failure modes were determined. Preferred materials were then selected for future study as the bore and rim alloys in this hybrid disk concept. Powder metallurgy superalloy LSHR at 15 micron grain size and single crystal superalloy LDS-1101+Hf were selected for further study, and future work is recommended to develop the hybrid disk concept.

Fiber reinforced superalloys for rocket engines

NASA Technical Reports Server (NTRS)

Petrasek, Donald W.; Stephens, Joseph R.

1988-01-01

High-pressure turbopumps for advanced reusable liquid-propellant rocket engines such as that for the Space Shuttle Main Engine (SSME) require turbine blade materials that operate under extreme conditions of temperature, hydrogen environment, high-cycle fatigue loading, thermal fatigue and thermal shock. Such requirements tax the capabilities of current blade materials. Based on projections of properties for tungsten fiber reinforced superalloy (FRS) composites, it was concluded that FRS turbine blades offer the potential of a several-fold increase in life and over a 200C increase in temperature capability over current SSME blade material. FRS composites were evaluated with respect to mechanical property requirements for SSME blade applications. Compared to the current blade material, the thermal shock resistance of FRS materials is excellent, two to nine times better, and their thermal fatigue resistance is equal to or higher than the current blade material. FRS materials had excellent low and high-cycle fatigue strengths, and thermal shock-induced surface microcracks had no influence on their fatigue strength. The material also exhibited negligible embrittlement when exposed to a hydrogen environment.

Fiber reinforced superalloys for rocket engines

NASA Technical Reports Server (NTRS)

Petrasek, Donald W.; Stephens, Joseph R.

1989-01-01

High pressure turbopumps for advanced reusable liquid propellant rocket engines such as that for the Space Shuttle Main Engine (SSME) require turbine blade materials that operate under extreme conditions of temperature, hydrogen environment, high-cycle fatigue loading, thermal fatigue and thermal shock. Such requirements tax the capabilities of current blade materials. Based on projections of properties for tungsten fiber reinforced superalloy (FRS) composites, it was concluded that FRS turbine blades offer the potential of a several fold increase in life and over a 200 C increase in temperature capability over the current SSME blade material. FRS composites were evaluated with respect to mechanical property requirements for SSME blade applications. Compared to the current blade material, the thermal shock resistance of FRS materials is excellent, two to nine times better, and their thermal fatigue resistance is equal to or higher than the current blade material. FRS materials had excellent low and high-cycle fatigue strengths, and thermal shock-induced surface microcracks had no influence on their fatigue strength. The material also exhibited negligible embrittlement when exposed to a hydrogen environment.

Superalloy Foams for Aeroshell Applications

NASA Technical Reports Server (NTRS)

Gayda, John; Padula, Santo, II

2001-01-01

Current thermal protection systems for reentry from space, such as that employed on the space shuttle, rely on ceramic tiles with ultra-low conductivity. These materials provide excellent thermal protection but are extremely fragile, easily degraded by environmental attack, and carry no structural loads. Future thermal protection systems being proposed in NASAs MITAS Program will attempt to combine thermal protection with improved durability and structural capability without significant increases in vehicle weight. This may be accomplished by combining several materials in a layered structure to obtain the desired function for aeroshell applications. One class of materials being considered for inclusion in this concept are high temperature metal foam. The objective of this paper was to fabricate low density, superalloy foams and conduct limited testing to evaluate their thermal and structural capabilities. Superalloys were chosen for evaluation as they possesses good strength and excellent environmental endurance over a wide range of temperatures. Utilizing superalloys as low density foams, with porosity contents greater than 90%, minimizes weight and thermal conductivity.

Effect of CeO2 on Cyclic Hot-Corrosion Behavior of Detonation-Gun Sprayed Cr3C2-NiCr Coatings on Ni-Based Superalloy

NASA Astrophysics Data System (ADS)

Saladi, Sekar; Menghani, Jyoti; Prakash, Satya

2015-03-01

The hot-corrosion behavior of detonation-gun sprayed Cr3C2-NiCr coatings with and without 0.4 wt.% CeO2 additive on Ni-based superalloy inconel-718 is comparatively discussed in the present study. Hot-corrosion studies were carried out at 900 °C for 100 cycles in Na2SO4-60%V2O5 molten salt environment under cyclic heating and cooling conditions on bare and coated superalloys. The thermo-gravimetric technique was used to establish kinetics of hot-corrosion. XRD, FESEM/EDAX, and EDX mapping techniques were used to analyze the corrosion products of bare and coated samples. The results indicate that Cr3C2-NiCr-CeO2-coated superalloy showed better hot-corrosion resistance as compared to bare and Cr3C2-NiCr-coated superalloys. The addition of CeO2 has improved micro-hardness, porosity, and surface roughness values of Cr3C2-NiCr-CeO2 coating. The overall weight gain and parabolic rate constant of Cr3C2-NiCr-CeO2-coated superalloy were found to be lowest in the present study signifying that the addition of CeO2 in Cr3C2-NiCr powder has contributed to the development of adherent and dense oxide scale on the coating at elevated temperature.

Experimental Investigation on High-Cycle Fatigue of Inconel 625 Superalloy Brazed Joints

NASA Astrophysics Data System (ADS)

Chen, Jianqiang; Demers, Vincent; Turner, Daniel P.; Bocher, Philippe

2018-04-01

The high-cycle fatigue performance and crack growth pattern of transient liquid phase-brazed joints in a nickel-based superalloy Inconel 625 were studied. Assemblies with different geometries and types of overlaps were vacuum-brazed using the brazing paste Palnicro-36M in conditions such as to generate eutectic-free joints. This optimal microstructure provides the brazed assemblies with static mechanical strength corresponding to that of the base metal. However, eutectic micro-constituents were observed in the fillet region of the brazed assembly due to an incomplete isothermal solidification within this large volume of filler metal. The fatigue performance increased significantly with the overlap distance for single-lap joints, and the best performance was found for double-lap joints. It was demonstrated that these apparent changes in fatigue properties according to the specimen geometry can be rationalized when looking at the fatigue data as a function of the local stress state at the fillet radii. Fatigue cracks were nucleated from brittle eutectic phases located at the surface of the fillet region. Their propagation occurred through the bimodal microstructure of fillet and the diffusion region to reach the base metal. High levels of crack path tortuosity were observed, suggesting that the ductile phases found in the microstructure may act as a potential crack stopper. The fillet region must be considered as the critical region of a brazed assembly for fatigue applications.

Calculation of Ceramic Phase Diagrams

DTIC Science & Technology

1979-11-30

Recent examples of the use of data bases and computer techniques in solw~ng problems associated with: in-situ formation of columbium, nickel and...examples of the use of data bases and computer techniques in solving problems associated with: in-situ formation of columbium, nickel and cobalt based...covers processing of in-situ eutectic composite formation in columbium, nickel and cobalt base superalloys, sigma phase formation in high temperature

Correlation of Thermally Induced Pores with Microstructural Features Using High Energy X-rays

NASA Astrophysics Data System (ADS)

Menasche, David B.; Shade, Paul A.; Lind, Jonathan; Li, Shiu Fai; Bernier, Joel V.; Kenesei, Peter; Schuren, Jay C.; Suter, Robert M.

2016-11-01

Combined application of a near-field High Energy Diffraction Microscopy measurement of crystal lattice orientation fields and a tomographic measurement of pore distributions in a sintered nickel-based superalloy sample allows pore locations to be correlated with microstructural features. Measurements were carried out at the Advanced Photon Source beamline 1-ID using an X-ray energy of 65 keV for each of the measurement modes. The nickel superalloy sample was prepared in such a way as to generate significant thermally induced porosity. A three-dimensionally resolved orientation map is directly overlaid with the tomographically determined pore map through a careful registration procedure. The data are shown to reliably reproduce the expected correlations between specific microstructural features (triple lines and quadruple nodes) and pore positions. With the statistics afforded by the 3D data set, we conclude that within statistical limits, pore formation does not depend on the relative orientations of the grains. The experimental procedures and analysis tools illustrated are being applied to a variety of materials problems in which local heterogeneities can affect materials properties.

Influence of Melt Superheating Treatment on Solidification Characteristics and Rupture Life of a Third-Generation Ni-Based Single-Crystal Superalloy

NASA Astrophysics Data System (ADS)

Su, Haijun; Wang, Haifeng; Zhang, Jun; Guo, Min; Liu, Lin; Fu, Hengzhi

2018-05-01

The influence of melt superheating treatment on the melt properties, solidification characteristics, and rupture life of a third-generation Ni-based single-crystal superalloy was investigated to reveal the critical temperature range of melt structure evolution and its effect on rupture life. The results showed that the viscosity of superalloy decreased but the surface tension increased with increasing superheating temperature. Two characteristic temperature points where the melt viscosity and undercooling degree suddenly change were determined to be 1600 °C and 1700 °C, respectively. Similarly, the stability of the solidification interface firstly improved and then weakened with increasing superheating temperature. The dendrite arms were well refined and the segregation was reduced at 1700 °C. In addition, the rupture life obtained at 1100 °C and 137 MPa increased by approximately 30 pct, approaching the rupture life of the corresponding superalloy containing 2 pct Ru, with increasing superheating temperature from 1500 °C to 1700 °C. When the melt was further heated to 1800 °C, the rupture life decreased. The evolutions of solidification characteristics and rupture life with increasing melt superheating temperature were attributed to changes in the melt structure.

Nickel-based Enzyme Systems*

PubMed Central

Ragsdale, Stephen W.

2009-01-01

Of the eight known nickel enzymes, all but glyoxylase I catalyze the use and/or production of gases central to the global carbon, nitrogen, and oxygen cycles. Nickel appears to have been selected for its plasticity in coordination and redox chemistry and is able to cycle through three redox states (1+, 2+, 3+) and to catalyze reactions spanning ∼1.5 V. This minireview focuses on the catalytic mechanisms of nickel enzymes, with an emphasis on the role(s) of the metal center. The metal centers vary from mononuclear to complex metal clusters and catalyze simple hydrolytic to multistep redox reactions. PMID:19363030

A new diffusion-inhibited oxidation-resistant coating for superalloys

NASA Technical Reports Server (NTRS)

Gedwill, M. A.; Glasgow, T. K.; Levine, S. R.

1981-01-01

A concept for enhanced protection of superalloys consists of adding an oxidation- and diffusion-resistant cermet layer between the superalloy and the outer oxidation-resistant metallic alloy coating. Such a duplex coating was compared with a physical-vapor-deposited (PVD) NiCrAlY coating in cyclic oxidation at 1150 C. The substrate alloy was MA 754 - an oxide-dispersion-strengthened superalloy that is difficult to coat. The duplex coating, applied by plasma spraying, outperformed the PVD coating on the basis of weight change and both macroscopic and metallographic observations.

NASA and Superalloys: A Customer, a Participant, and a Referee

NASA Technical Reports Server (NTRS)

Nathal, Michael V.

2008-01-01

NASA has had a long history of research and development in the field of superalloys. These efforts have continued today, where the latest advancements in turbine disk and blade technologies are being developed. Although NASA does support military flight systems, its predominant role is in supporting civilian air transportation systems, and thus has goals for improving fuel efficiency, emissions, noise, and safety of today s aircraft. NASA has traditionally served several distinct but complimentary roles as participants in multi-disciplinary research teams, as customers who fund research and development efforts at industry and universities, and as referees who can address broad issues that affect the entire aeronautics community. Because of our longer range viewpoint, we can take on higher risk, higher reward research topics. NASA can also serve as an intermediary between the basic research performed primarily at universities and the development efforts emphasized by industry. By interacting with individual companies, NASA can identify areas of general interest and problems common to a large portion of the aeronautics community, and devise programs aimed at solving these problems. In space missions, NASA is a direct customer responsible for developing vehicles. In the case of the Space Shuttle, NASA has worked with various contractors to design and build numerous components out of superalloys. Another fascinating area for the use of superalloys is in power systems for long life applications in space. Potential missions include providing electric power for deep space missions, surface rovers, including lunar and Mars, and stationary power generators on the lunar surface.

NASA and Superalloys: A Customer, a Participant, and a Referee

NASA Technical Reports Server (NTRS)

Nathal, Michael V.

2008-01-01

NASA has had a long history of research and development in the field of superalloys. These efforts have continued today, where the latest advancements in turbine disk and blade technologies are being developed Although NASA does support military flight systems, it s predominant role is in supporting civilian air transportation systems, and thus has goals for improving fuel efficiency, emissions, noise, and safety of today s aircraft. NASA has traditionally served several distinct but complimentary roles as participants in multi-disciplinary research teams, as customers who fund research and development efforts at industry and universities, and as referees who can address broad issues that affect the entire aeronautics community. Because of our longer range viewpoint, we can take on higher risk, higher reward research topics. NASA can also serve as an intermediary between the basic research performed primarily at universities and the development efforts emphasized by industry. By interacting with individual companies, NASA can identify areas of general interest and problems common to a large portion of the aeronautics community, and devise programs aimed at solving these problems. In space missions, NASA is a direct customer responsible for developing vehicles. In the case of the Space Shuttle, NASA has worked with various contractors to design and build numerous components out of superalloys. Another fascinating area for the use of superalloys is in power systems for long life applications in space. Potential missions include providing electric power for deep space missions, surface rovers, including lunar and Mars, and stationary power generators on the lunar surface.

Low Density, High Creep Resistant Single Crystal Super Alloy for Turbine Airfoils

NASA Technical Reports Server (NTRS)

MacKay, Rebecca A. (Inventor); Gabb, Timothy P. (Inventor); Smialek, James L. (Inventor); Nathal, Michael V. (Inventor)

2007-01-01

A nickel-base superalloy article for use in turbines has increased creep resistance and lower density. The superalloy article includes, as measured in % by weight, 6.0-12.0% Mo, 5.5-6.5%Al, 3.0-7.0% Ta, 0-15% Co, 2.0-6.0% Cr, 1.0-4.0% Re, 0-1.5% W, 0-1.5% Ru, 0-2.0% Ti, 0-3.0% Nb, 0-0.2% Hf, 0-0.02% Y, 0.001-0.005% B, 0.01-0.04% C, and a remainder including nickel plus impurities.

Determination of γ/ γ' Lattice Misfit in Ni-Based Single-Crystal Superalloys at High Temperatures by Neutron Diffraction

NASA Astrophysics Data System (ADS)

Huang, Shenyan; An, Ke; Gao, Yan; Suzuki, Akane

2018-03-01

Constrained γ/ γ' lattice misfit as a function of temperature (room temperature, 871 °C, 982 °C, 1093 °C, and 1204 °C) is measured by neutron diffraction on the first-generation Ni-based single-crystal superalloy René N4 and second-generation superalloys René N5, CMSX4, and PWA1484. All the alloys studied show negative misfit at temperatures above 871 °C. For René N4, René N5, and PWA1484, the misfit becomes less negative at temperatures above 1093 °C, possibly due to either the chemistry effect or internal stress relaxation. The magnitude of the misfit shows a qualitative agreement with Caron's misfit model based on Vegard's coefficients. The Re-free alloy René N4 was found to have a larger γ lattice parameter and γ/ γ' misfit due to higher fractions of Cr, Ti, and Mo. After 100 hours of annealing at high temperatures, René N5 shows a more negative misfit than the misfit after the standard heat treatment.

Gamma prime precipitation modeling and strength responses in powder metallurgy superalloys

NASA Astrophysics Data System (ADS)

Mao, Jian

Precipitation-hardened nickel-based superalloys have been widely used as high temperature structural materials in gas turbine engine applications for more than 50 years. Powder metallurgy (P/M) technology was introduced as an innovative manufacturing process to overcome severe segregation and poor workability of alloys with high alloying contents. The excellent mechanical properties of P/M superalloys also depend upon the characteristic microstructures, including grain size and size distribution of gamma' precipitates. Heat treatment is the most critical processing step that has ultimate influences on the microstructure, and hence, on the mechanical properties of the materials. The main objective of this research was to study the gamma ' precipitation kinetics in various cooling circumstances and also study the strength response to the cooling history in two model alloys, Rne88DT and U720LI. The research is summarized below: (1) An experimental method was developed to allow accurate simulation and control of any desired cooling profile. Two novel cooling methods were introduced: continuous cooling and interrupt cooling. Isothermal aging was also carried out. (2) The growth and coarsening kinetics of the cooling gamma' precipitates were experimentally studied under different cooling and aging conditions, and the empirical equations were established. It was found that the cooling gamma' precipitate versus the cooling rate follows a power law. The gamma' precipitate size versus aging time obeys the LSW cube law for coarsening. (3) The strengthening of the material responses to the cooling rate and the decreasing temperature during cooling was investigated in both alloys. The tensile strength increases with the cooling rate. In addition, the non-monotonic response of strength versus interrupt temperature is of great interest. (4) An energy-driven model integrated with the classic growth and coarsen theories was successfully embedded in a computer program developed to

Structural and crystal orientation analysis of Al-Si coating on Ni-based superalloy by means of EBSD technique

NASA Astrophysics Data System (ADS)

Muslimin, A. N.; Sugiarti, E.; Aritonang, T.; Purawiardi, R. I.; Desiati, R. D.

2018-03-01

Ni-based superalloy is widely used for high performance components in power generation turbine due to its excellent mechanical properties. However, Ni-based superalloy has low oxidation resistantance. Therefore, surface coating is required to improve oxidation resistance at high temperatures. Al-Si as a coting material was successfully co-deposited on Ni-based substrate by pack cementation method at 900 °C for about 4 hours. The oxidation test was carried out at high temperature of 1000 °C for 100 hours. Micro structural characterization and analysis on crystal orientation were perfomed by using Field Emission Scanning Electron Microscope (FE-SEM) and Electron Back Scatter Diffraction (EBSD) technique, respectively. The results showed that the coating layer with a homogenous layer and had a thickness of 53 μm consisting of β-NiAl with cubic structure and Ni2Al3 with hexagonal structure. TGO layer was developed after oxidation and had a thickness of about 5 μm consisting of α-Al2O3 and spinel NiCr2O4. The phase composition map and crystal orientation acquired by EBSD technique was also discussed both in TGO and coating layers.

Properties and microstructures for dual alloy combinations of three superalloys with alloy 901

NASA Technical Reports Server (NTRS)

Harf, F. H.

1985-01-01

Dual alloy combinations have potential for use in aircraft engine components such as turbine disks where a wide range of stress and temperature regimes exists during operation. Such alloy combinations may directly result in the conservation of elements which are costly or not available domestically. Preferably, a uniform heat treatment yielding good properties for both alloys should be used. Dual alloy combinations of iron rich Alloy 901 with nickel base superalloys Rene 95, Astroloy, or MERL 76 were not isostatically pressed from prealloyed powders. Individual alloys, alloy mixtures, and layered alloy combinations were given the heat treatments specified for their use in turbine disks or appropriate for Alloy 901. Selected specimens were overaged for 1500 hr at 650 C. Metallographic examinations revealed the absence of phases not originally present in either alloy of a combination. Mechanical tests showed adequate properties in combinations of Rene 95 or Astroloy with Alloy 901 when given the Alloy 901 heat treatment. Combinations with MERL 76 had better properties when given the MERL 76 heat treatment. The results indicate that these combinations are promising candidates for use in turbine disks.

Effect of Alloying Additions on Oxidation Behaviors of Ni-Fe Based Superalloy for Ultra-Supercritical Boiler Applications

NASA Astrophysics Data System (ADS)

Lu, Jintao; Yang, Zhen; Zhao, Xinbao; Yan, Jingbo; Gu, Y.

A new kind of Ni-Fe-based superalloy is designed recently for 750 °C-class A-USC boiler tube. The oxidation behavior of the designed alloys with various combinations of anti-oxidation additions, Cr, Al and Si, was investigated at 750 °C and 850 °C, respectively. The results indicated that the oxidation rate of tested alloys decreased with the increase of the sum of additions. Cr addition may drop the relative constant of parabolic rate greatly when temperature is raised. But the oxide scale, mainly consisted of NiCr spinel at 750 °C and NiCrMn spinel at 850 °C, was similar while the Cr content is in a range of 20-25 wt.% at tested temperatures. Al addition, however, showed the best effective to reduce the oxidation rates. Internal Al-rich oxide was observed at the scale/metal interface for alloys added with high content of Al and was increased with Al content increase. Very tiny difference between the oxide scales of the Si-added alloys was identified when Si content varies among 0.02-0.05 wt.%. Basing on these results, this presentation discussed the optimum combination of anti-oxidation additions as well as oxidation mechanisms in the designed Ni-Fe-base superalloy.

Nickel speciation in several serpentine (ultramafic) topsoils via bulk synchrotron-based techniques

DOE Office of Scientific and Technical Information (OSTI.GOV)

Siebecker, Matthew G.; Chaney, Rufus L.; Sparks, Donald L.

2017-07-01

Serpentine soils have elevated concentrations of trace metals including nickel, cobalt, and chromium compared to non-serpentine soils. Identifying the nickel bearing minerals allows for prediction of potential mobility of nickel. Synchrotron-based techniques can identify the solid-phase chemical forms of nickel with minimal sample treatment. Element concentrations are known to vary among soil particle sizes in serpentine soils. Sonication is a useful method to physically disperse sand, silt and clay particles in soils. Synchrotron-based techniques and sonication were employed to identify nickel species in discrete particle size fractions in several serpentine (ultramafic) topsoils to better understand solid-phase nickel geochemistry. Nickel commonlymore » resided in primary serpentine parent material such as layered-phyllosilicate and chain-inosilicate minerals and was associated with iron oxides. In the clay fractions, nickel was associated with iron oxides and primary serpentine minerals, such as lizardite. Linear combination fitting (LCF) was used to characterize nickel species. Total metal concentration did not correlate with nickel speciation and is not an indicator of the major nickel species in the soil. Differences in soil texture were related to different nickel speciation for several particle size fractionated samples. A discussion on LCF illustrates the importance of choosing standards based not only on statistical methods such as Target Transformation but also on sample mineralogy and particle size. Results from the F-test (Hamilton test), which is an underutilized tool in the literature for LCF in soils, highlight its usefulness to determine the appropriate number of standards to for LCF. EXAFS shell fitting illustrates that destructive interference commonly found for light and heavy elements in layered double hydroxides and in phyllosilicates also can occur in inosilicate minerals, causing similar structural features and leading to false positive

Bipolar Nickel-Metal Hydride Battery Being Developed

NASA Technical Reports Server (NTRS)

Manzo, Michelle A.

1998-01-01

The NASA Lewis Research Center has contracted with Electro Energy, Inc., to develop a bipolar nickel-metal hydride battery design for energy storage on low-Earth-orbit satellites. The objective of the bipolar nickel-metal hydride battery development program is to approach advanced battery development from a systems level while incorporating technology advances from the lightweight nickel electrode field, hydride development, and design developments from nickel-hydrogen systems. This will result in a low-volume, simplified, less-expensive battery system that is ideal for small spacecraft applications. The goals of the program are to develop a 1-kilowatt, 28-volt (V), bipolar nickel-metal hydride battery with a specific energy of 100 watt-hours per kilogram (W-hr/kg), an energy density of 250 W-hr/liter and a 5-year life in low Earth orbit at 40-percent depth-of-discharge.

Structure-property characterization of rheocast and VADER processed IN-100 superalloy. Ph.D. Thesis. Final Report

NASA Technical Reports Server (NTRS)

Cheng, J. J. A.; Apelian, D.

1985-01-01

Two recent solidification processes have been applied in the production of IN-100 nickel-base superalloy: rheocasting and vacuum arc double electrode remelting (VADER). A detailed microstructural examination has been made of the products of these two processes; associated tensile strength and fatigue crack propagation (FCP) rate at an elevated temperature were evaluated. In rheocasting, processing variables that have been evaluated include stirring speed, isothermal stirring time and volume fraction solid during isothermal stirring. VADER processed IN-100 was purchased from Special Metals Corp., New Hartford, NY. As-cast ingots were subjected to hot isostatic pressing (HIP) and heat treatment. Both rheocasting and VADER processed materials yield fine and equiaxed spherical structures, with reduced macrosegregation in comparison to ingot materials. The rheocast structures are discussed on the basis of the Vogel-Doherty-Cantor model of dendrite arm fragmentation. The rheocast ingots evaluated were superior in yield strength to both VADER and commercially cast IN-100 alloy. Rheocast and VADER ingots may have higher crack propagation resistance than P/M processed material.

Effects of Rhenium Addition on the Temporal Evolution of the Nanostructure and Chemistry of a Model Ni-Cr-Al Superalloy. 1; Experimental Observations

NASA Technical Reports Server (NTRS)

Yoon, Kevin E.; Noebe, Ronald D.; Seidman, David N.

2006-01-01

The temporal evolution of the nanostructure and chemistry of a model Ni-8.5 at.% Cr-10 at. % Al alloy, with the addition of 2 at.% Re, aged at 1073 K from 0.25 to 264 h, was studied. Transmission electron microscopy and atom-probe tomography were used to measure the number density and mean radius of the gamma prime (L1(sub 2) structure)-precipitates and the chemistry of the gamma prime-precipitates and the gamma (face-centered cubic)-matrix, including the partitioning behavior of all alloying elements between the gamma- and gamma prime-phases and the segregation behavior at gamma/gamma prime interfaces. The precipitates remained spheroidal for an aging time of up to 264 h and, unlike commercial nickel-based superalloys containing Re, there was not confined (nonmonotonic) Re segregation at the gamma/gamma prime interfaces.

Microstructure and Mechanical Properties in Gamma(face-centered cubic) + Gamma Prime(L12) Precipitation-Strengthened Cobalt-based Superalloys

NASA Astrophysics Data System (ADS)

Bocchini, Peter J.

High-temperature structural alloys for aerospace and energy applications have long been dominated by Ni-based superalloys, whose high-temperature strength and creep resistance can be attributed to a two-phase microstructure consisting of a large volume fraction of ordered gamma'(L12)-precipitates embedded in a disordered gamma(f.c.c.)-matrix. These alloys exhibit excellent mechanical behavior and thermal stability, but after decades of incremental improvement, are nearing the theoretical limit of their operating temperatures. In 2006, an analogous gamma(f.c.c.) + gamma'(L12) microstructure was identified in the Co-Al-W ternary system with liquidus and solidus temperatures 50-150 °C higher than conventional Ni-based superalloys. The work herein focuses on assessing the effects of alloying additions on microstructure and mechanical behavior in an effort to lay the foundations for understanding this emerging alloy system. A variety of Co-based superalloys are investigated in order to study fundamental materials properties and to address key engineering challenges. Coarsening rate constants and temporal exponents are measured for gamma'(L1 2)-precipitates in a ternary Co-Al-W alloy aged at 650 °C and 750 °C. A series of Co-Al-W-B-Zr alloys are cast to study the influence of segregation of B and Zr to grain boundaries (GBs) on mechanical properties. Co-Ni-Al-W-Ti alloys with various amounts of Al, W, and Ti are cast in order to fabricate Co-based superalloys with decreased density and increased gamma'(L1 2)-solvus temperature. 2-D dislocation dynamics modeling is employed to predict how gamma'(L12)-precipitate size and volume fraction affect the mechanical properties of Ni- and Co-based superalloys. Compositional information such as phase concentrations, partitioning behavior, and GB segregation are measured with local electrode atom probe (LEAP) tomography in alloys with fine microstructures and with scanning electron microscope (SEM) electron dispersive x

Simulation-Based Extreme Value Marked Correlations in Fatigue of Advanced Engineering Alloys (PREPRINT)

DTIC Science & Technology

2010-04-01

000 the response of damage dependent processes like fatigue crack formation, a framework is needed that accounts for the extreme value life...many different damage processes (e.g. fatigue, creep, fracture). In this work, multiple material volumes for both IN100 and Ti-6Al-4V are simulated via...polycrystalline P/M Ni-base superalloy IN100 Typically, fatigue damage formation in polycrystalline superalloys has been linked to the existence of

A study of life prediction differences for a nickel-base Alloy 690 using a threshold and a non-threshold model

NASA Astrophysics Data System (ADS)

Young, B. A.; Gao, Xiaosheng; Srivatsan, T. S.

2009-10-01

In this paper we compare and contrast the crack growth rate of a nickel-base superalloy (Alloy 690) in the Pressurized Water Reactor (PWR) environment. Over the last few years, a preponderance of test data has been gathered on both Alloy 690 thick plate and Alloy 690 tubing. The original model, essentially based on a small data set for thick plate, compensated for temperature, load ratio and stress-intensity range but did not compensate for the fatigue threshold of the material. As additional test data on both plate and tube product became available the model was gradually revised to account for threshold properties. Both the original and revised models generated acceptable results for data that were above 1 × 10 -11 m/s. However, the test data at the lower growth rates were over-predicted by the non-threshold model. Since the original model did not take the fatigue threshold into account, this model predicted no operating stress below which the material would effectively undergo fatigue crack growth. Because of an over-prediction of the growth rate below 1 × 10 -11 m/s, due to a combination of low stress, small crack size and long rise-time, the model in general leads to an under-prediction of the total available life of the components.

Computer Aided Design of Ni-Based Single Crystal Superalloy for Industrial Gas Turbine Blades

NASA Astrophysics Data System (ADS)

Wei, Xianping; Gong, Xiufang; Yang, Gongxian; Wang, Haiwei; Li, Haisong; Chen, Xueda; Gao, Zhenhuan; Xu, Yongfeng; Yang, Ming

The influence of molybdenum, tungsten and cobalt on stress-rupture properties of single crystal superalloy PWA1483 has been investigated using the simulated calculation of JMatPro software which ha s been widely used to develop single crystal superalloy, and the effect of alloying element on the stability of strengthening phase has been revealed by using the Thermo-Calc software. Those properties calculation results showed that the increasing of alloy content could facilitate the precipitation of TCP phases and increase the lattice misfit between γ and γ' phase, and the effect of molybdenum, tantalum was the strongest and that of cobalt was the weakest. Then the chemical composition was optimized, and the selected compositions showed excellent microstructure stability and stress-rupture properties by the confirmation of d-electrons concept and software calculation.

Microstructural characteristics of σ phase and P phase in Ru-containing single crystal superalloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Huo, Jiajie, E-mail: jiajiehuo0618@163.com

Microstructural instability caused by topologically close-packed (TCP) phase precipitation restricts the useful compositional range of advanced Ni-base single crystal superalloys in industrial applications. Limited systematic investigations of TCP formers (Cr and Mo) additions on microstructural evolution of both the σ phase and the P phase in Ru-containing single crystal superalloys have been reported. In this study, the microstructural characteristics of σ phase and P phase were investigated in three Ru-containing superalloys with different levels of Cr and Mo additions at 950 °C and 1100 °C by using phase extraction, X-ray diffraction, scanning electron microscope and high resolution transmission electron microscopy.more » The experimental results indicated that the high level additions of Cr and Mo promoted the formation of σ phase and P phase, respectively. The amount of σ phase was much higher than that of P phase after long term exposure at 950 °C and 1100 °C. The sheet-like σ phase existed in the alloy with higher Cr addition after thermal exposure at 950 °C and 1100 °C for 1000 h, while the needle-like P phase precipitated in high Mo content alloy after thermal exposure at 1100 °C for 1000 h and the intergrowth of σ phase and P phase was observed after thermal exposure at 950 °C for 500 h. Both the σ phase and P phase were enriched in Re, W, Cr and Mo, but the σ phase contained more Re and Cr while the P phase contained more Mo and Ni, and Ru was found in both phases. The nucleation of σ phase was much easier than P phase due to the more ledge steps in the interfacial structure between σ phase and matrix, as well as the higher partitioning ratios of Re, Cr and Mo. This study is helpful to understand the microstructural evolution of σ phase and P phase, and to optimize the alloy design in Ru-containing superalloys. - Highlights: •Microstructures of σ phase and P phase were characterized in detail. •Cr and Mo influenced the

Study of the effects of gaseous environmental on the hot corrosion of superalloy materials

NASA Technical Reports Server (NTRS)

Smeggil, J. G.

1981-01-01

Studies have been conducted to examine the effect of low concentrations of NaCl(g) on the high temperature oxidation behavior of complex superalloys and potential coating formulations modified by silicon and reactive element (i.e., yttrium and hafnium) additions. Depending on alloy composition, a variety of effects were thermogravimetrically produced. Aluminum free alloys such as MAR-M509 and Hastelloy X with molybdenum and tungsten in solid solution showed accelerated (or breakaway) kinetics similar to that observed for Ni-Cr alloys. For IN-792, an alloy high in chromium and low in aluminum, molybdenum and tungsten present in solid solution does not adversely affect oxidation kinetics in the presence of NaCl(g). On the other hand, nickel-base alloys high in aluminum and molybdenum are catastrophically attacked by NaCl-bearing atmospheres. Silicon additions were, in general, observed to slightly improve the oxidation resistance of Ni, Ni-40Cr and CoCrAlY compositions in NaCl(g)-bearing atmospheres. To the degree that processes responsible for Al2O3 whisker formation deleteriously affect protective scale adherence, the addition of yttrium or hafnium can inhibit such whisker growth.

Computer simulation of morphological evolution and rafting of {gamma}{prime} particles in Ni-based superalloys under applied stresses

DOE Office of Scientific and Technical Information (OSTI.GOV)

Li, D.Y.; Chen, L.Q.

Mechanical properties of Ni-based superalloys are strongly affected by the morphology, distribution, and size of {gamma}{prime} precipitates in the {gamma} matrix. The main purpose of this paper is to propose a continuum field approach for modeling the morphology and rafting kinetics of coherent precipitates under applied stresses. This approach can be used to simulate the temporal evolution of arbitrary morphologies and microstructures without any a priori assumption. Recently, the authors applied this approach to the selected variant growth in Ni-Ti alloys under applied stresses using an inhomogeneous modulus approximation. For the {gamma}{prime} precipitates in Ni-based superalloys, the eigenstrain is dilatational,more » and hence the {gamma}{prime} morphological evolution can be affected by applied stresses only when the elastic modulus is inhomogeneous. In the present work, the elastic inhomogeneity was taken into account by reformulating a sharp-interface elasticity theory developed recently by Khachaturyan et al. in terms of diffuse interfaces. Although the present work is for a {gamma}{prime} {minus} {gamma} system, this model is general in a sense that it can be applied to other alloy systems containing coherent ordered intermetallic precipitates with elastic inhomogeneity.« less

Factors affecting miniature Izod impact strength of tungsten-fiber-metal-matrix

NASA Technical Reports Server (NTRS)

Winsa, E. A.; Petrasek, D. W.

1973-01-01

The miniature Izod and Charpy impact strengths of copper, copper-nickel, and nickel-base superalloy uniaxially reinforced with continuous tungsten fibers were studied. In most cases, impact strength was increased by increasing fiber or matrix toughness, decreasing fibermatrix reaction, increasing test temperature, hot working, or heat treating. Notch sensitivity was reduced by increasing fiber content or matrix toughness. An equation relating impact strength to fiber and matrix properties and fiber content was developed. Program results imply that tungsten alloy-fiber/superalloy matrix composites can be made with adequate impact resistance for turbine blade or vane applications.

Investigations on Microstructure and Corrosion behavior of Superalloy 686 weldments by Electrochemical Corrosion Technique

NASA Astrophysics Data System (ADS)

Arulmurugan, B.; Manikandan, M.

2018-02-01

In the present study, microstructure and the corrosion behavior of Nickel based superalloy 686 and its weld joints has been investigated by synthetic sea water environment. The weldments were fabricated by Gas Tungsten Arc Welding (GTAW) and Pulsed Current Gas Tungsten Arc Welding (PCGTAW) techniques with autogenous mode and three different filler wires (ERNiCrMo-4, ERNiCrMo-10 and ERNiCrMo-14). Microstructure and Scanning electron microscope examination was carried out to evaluate the structural changes in the fusion zones of different weldments. Energy Dispersive X-ray Spectroscopy (EDS) analysis was carried out to evaluate the microsegregation of alloying elements in the different weld joints. Potentiodynamic polarization study was experimented on the base metal and weld joints in the synthetic sea water environment to evaluate the corrosion rate. Tafel’s interpolation technique was used to obtain the corrosion rate. The microstructure examination revealed that the fine equiaxed dendrites were observed in the pulsed current mode. EDS analysis shows the absence of microsegregation in the current pulsing technique. The corrosion rates of weldments are compared with the base metal. The results show that the fine microstructure with the absence of microsegregation in the PCGTA weldments shows improved corrosion resistance compared to the GTAW. Autogenous PCGTAW shows higher corrosion resistance irrespective of all weldments employed in the present study.

Response to Discussion of "Investigation of Oxide Bifilms in Investment Cast Superalloy IN100 Part I and II"

NASA Astrophysics Data System (ADS)

Kaplan, M. A.; Fuchs, G. E.

2017-10-01

In his most recent letter (Campbell in Met Trans A, 2017), Professor Campbell provides additional comments on Kaplan and Fuchs papers "Oxides Bifilms in Superalloy: IN100, Parts I and II (Met Trans A 47A:2346-2361, 2016; Met Trans A 47A:2362-2375, 2016) and on their response to his initial comments (Met Trans A 47A:3806-3809, 2016). In this recent submission, Campbell provides some very interesting thoughts on why bifilms were not observed by Kaplan and Fuchs and creates a new theory for the formation of defects referred to as bifilms. However, Campbell again provides no evidence to substantiate the presence of bifilms in Ni-base superalloys or his newly theorized mechanism. The vast majority of Campbell's comments are based solely on the re-interpretation of the photomicrographs and the data reported in the literature, including those presented by Kaplan and Fuchs (Met Trans A 47A:2346-2361, 2016; Met Trans A 47A:2362-2375, 2016). Campbell claims that bifilms are present throughout Ni-base superalloys, even though no one else has reported the presence of bifilms in Ni-base superalloys. In re-interpreting the data and images, Campbell ignores the extensive surface characterization results reported by Kaplan and Fuchs (Met Trans A 47A:2346-2361, 2016; Met Trans A 47A:2362-2375, 2016) that clearly indicate that there are no oxide films or bifilms on the fracture surfaces examined. Please note that this discussion of Campbell's most recent letter will be limited to Ni-base superalloys, since that is the subject of the research reported by Kaplan and Fuchs.

A comparative study of quantitative microsegregation analyses performed during the solidification of the Ni-base superalloy CMSX-10

DOE Office of Scientific and Technical Information (OSTI.GOV)

Seo, Seong-Moon, E-mail: castme@kims.re.kr; Jeong, Hi-Won; Ahn, Young-Keun

Quantitative microsegregation analyses were systematically carried out during the solidification of the Ni-base superalloy CMSX-10 to clarify the methodological effect on the quantification of microsegregation and to fully understand the solidification microstructure. Three experimental techniques, namely, mushy zone quenching (MZQ), planar directional solidification followed by quenching (PDSQ), and random sampling (RS), were implemented for the analysis of microsegregation tendency and the magnitude of solute elements by electron probe microanalysis. The microprobe data and the calculation results of the diffusion field ahead of the solid/liquid (S/L) interface of PDSQ samples revealed that the liquid composition at the S/L interface is significantlymore » influenced by quenching. By applying the PDSQ technique, it was also found that the partition coefficients of all solute elements do not change appreciably during the solidification of primary γ. All three techniques could reasonably predict the segregation behavior of most solute elements. Nevertheless, the RS approach has a tendency to overestimate the magnitude of segregation for most solute elements when compared to the MZQ and PDSQ techniques. Moreover, the segregation direction of Cr and Mo predicted by the RS approach was found to be opposite from the results obtained by the MZQ and PDSQ techniques. This conflicting segregation behavior of Cr and Mo was discussed intensively. It was shown that the formation of Cr-rich areas near the γ/γ′ eutectic in various Ni-base superalloys, including the CMSX-10 alloy, could be successfully explained by the results of microprobe analysis performed on a sample quenched during the planar directional solidification of γ/γ′ eutectic. - Highlights: • Methodological effect on the quantification of microsegregation was clarified. • The liquid composition at the S/L interface was influenced by quenching. • The segregation direction of Cr varied depending on

Major Effects of Nonmetallic Inclusions on the Fatigue Life of Disk Superalloy Demonstrated

NASA Technical Reports Server (NTRS)

Gabb, Timothy P.; Telesman, Jack; Kantzos, Peter T.; Bonacuse, Peter J.; Barrie, Robert L.

2002-01-01

The fatigue properties of modern powder metallurgy disk alloys can vary because of the different steps of materials and component processing and machining. Among these variables, the effects of nonmetallic inclusions introduced during the powder atomization and handling processes have been shown to significantly degrade low-cycle fatigue life. The levels of inclusion contamination have, therefore, been reduced to less than 1 part per million in state-of-the-art nickel disk powder-processing facilities. Yet the large quantities of compressor and turbine disks weighing from 100 to over 1000 lb have enough total volume and surface area for these rare inclusions to still be present and limit fatigue life. The objective of this study was to investigate the effects on fatigue life of these inclusions, as part of the Crack Resistant Disk Materials task within the Ultra Safe Propulsion Project. Inclusions were carefully introduced at elevated levels in a nickel-base disk superalloy, U720, produced using powder metallurgy processing. Multiple strain-controlled fatigue tests were then performed on extracted test specimens at 650 C. Analyses were performed to compare the low-cycle fatigue lives and failure initiation sites as functions of inclusion content and fatigue conditions. Powder of the nickel-base superalloy U720 was atomized in argon at Special Metals Corporation, Inc., using production-scale high-cleanliness powder-processing facilities and handling practices. The powder was then passed through a 270-mesh screen. One portion of this powder was set aside for subsequent consolidation without introduced inclusions. Two other portions of this powder were seeded with alumina inclusions. Small, polycrystalline soft (Type 2) inclusions of about 50 mm diameter were carefully prepared and blended into one powder lot, and larger hard (Type 1) inclusions of about 150 mm mean diameter were introduced into the other seeded portion of powder. All three portions of powder were

Design of Novel Precipitate-Strengthened Al-Co-Cr-Fe-Nb-Ni High-Entropy Superalloys

NASA Astrophysics Data System (ADS)

Antonov, Stoichko; Detrois, Martin; Tin, Sammy

2018-01-01

A series of non-equiatomic Al-Co-Cr-Fe-Nb-Ni high-entropy alloys, with varying levels of Co, Nb and Fe, were investigated in an effort to obtain microstructures similar to conventional Ni-based superalloys. Elevated levels of Co were observed to significantly decrease the solvus temperature of the γ' precipitates. Both Nb and Co in excessive concentrations promoted the formation of Laves and NiAl phases that formed either during solidification and remained undissolved during homogenization or upon high-temperature aging. Lowering the content of Nb, Co, or Fe prevented the formation of the eutectic type Laves. In addition, lowering the Co content resulted in a higher number density and volume fraction of the γ' precipitates, while increasing the Fe content led to the destabilization of the γ' precipitates. Various aging treatments were performed which led to different size distributions of the strengthening phase. Results from the microstructural characterization and hardness property assessments of these high-entropy alloys were compared to a commercial, high-strength Ni-based superalloy RR1000. Potentially, precipitation-strengthened high-entropy alloys could find applications replacing Ni-based superalloys as structural materials in power generation applications.

Thermal and mechanical treatments for nickel and some nickel-base alloys: Effects on mechanical properties

NASA Technical Reports Server (NTRS)

Hall, A. M.; Beuhring, V. F.

1972-01-01

This report deals with heat treating and working nickel and nickel-base alloys, and with the effects of these operations on the mechanical properties of the materials. The subjects covered are annealing, solution treating, stress relieving, stress equalizing, age hardening, hot working, cold working, combinations of working and heat treating (often referred to as thermomechanical treating), and properties of the materials at various temperatures. The equipment and procedures used in working the materials are discussed, along with the common problems that may be encountered and the precautions and corrective measures that are available.

Atom Probe Tomography Analysis of the Distribution of Rhenium in Nickel Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mottura, A.; Warnken, N; Miller, Michael K

2010-01-01

Atom probe tomography (APT) is used to characterise the distributions of rhenium in a binary Ni-Re alloy and the nickel-based single-crystal CMSX-4 superalloy. A purpose-built algorithm is developed to quantify the size distribution of solute clusters, and applied to the APT datasets to critique the hypothesis that rhenium is prone to the formation of clusters in these systems. No evidence is found to indicate that rhenium forms solute clusters above the level expected from random fluctuations. In CMSX-4, enrichment of Re is detected in the matrix phase close to the matrix/precipitate ({gamma}/{gamma}{prime}) phase boundaries. Phase field modelling indicates that thismore » is due to the migration of the {gamma}/{gamma}{prime} interface during cooling from the temperature of operation. Thus, neither clustering of rhenium nor interface enrichments can be the cause of the enhancement in high temperature mechanical properties conferred by rhenium alloying.« less

Advanced nickel-hydrogen cell configuration study

NASA Technical Reports Server (NTRS)

1983-01-01

Long-term trends in the evolution of space power technology point toward increased payload power demand which in turn translates into both higher battery system charge storage capability and higher operating voltages. State of the art nickel-hydrogen cells of the 50 to 60 Wh size, packaged in individual pressure vessels, are capable of meeting the required cycle life for a wide range of anticipated operating conditions; however, they provided several drawbacks to battery system integrated efforts. Because of size, high voltage/high power systems require integrating hundreds of cells into the operating system. Packaging related weight and volume inefficiencies degrade the energy density and specific energy of individual cells currently at 30 Wh/cudm and 40 Wh/kg respectively. In addition, the increased parts count and associated handling significantly affect the overall battery related costs. Spacecraft battery systems designers within industry and Government realize that to reduce weight, volume, and cost requires increases in the capacity of nickel-hydrogen cells.

The fatigue damage behavior of a single crystal superalloy

NASA Technical Reports Server (NTRS)

Mcgaw, Michael A.

1988-01-01

The uniaxial fatigue behavior of a single crystal superalloy, PWA 1480, is described. Both monotonic tensile and constant amplitude fatigue tests were conducted at room temperature, in an effort to assess the applicability of polycrystalline-based fatigue life prediction methods to a single crystal superalloy. The observed constant amplitude behavior correlated best using a stress-based life criterion. Nearly all specimens failed at surface or slightly subsurface microporosity; this is thought to be responsible for the unusually large amount of scatter in the test results. An additional term is developed in the stress-life equation for the purpose of accounting for the effect of microporosity on fatigue life. The form chosen is a function of the effective area of the failure-producing microporosity projected on a plane perpendicular to the loading axis, as well as the applied stress. This additional term correlated the data to within factors of two on life. Although speculative, extrapolation of the microporosity relation to zero micropore area indicates that approximately an order of magnitude improvement in fatigue life should result.

Urinary nickel excretion in populations living in the proximity of two russian nickel refineries: a Norwegian-Russian population-based study.

PubMed Central

Smith-Sivertsen, T; Tchachtchine, V; Lund, E; Bykov, V; Thomassen, Y; Norseth, T

1998-01-01

The Russian nickel refineries located in the cities of Nikel and Zapolyarny close to the Norwegian border are responsible for extensive sulfur dioxide and nickel pollution, as well as severe ecological damage in both countries. The aim of our study was to investigate human nickel exposure in the populations living on both sides of the Norwegian-Russian border. The design was a cross-sectional population-based study of adults aged 18-69 years residing in Sor-Varanger municipality, Norway, and Nikel and Zapolyarny, Russia, during 1994 and 1995. Individual exposure to nickel was assessed by measurements of nickel in urine using electrothermal atomic absorption spectrometry. For controls, urine was collected from adults in the Russian cities of Apatity and Umba (Kola Peninsula) and the Norwegian city of Tromso, all of which are locations without nearby point sources of nickel. Altogether 2,233 urine specimens were analysed for nickel. People living in Nikel had the highest concentrations (median 3.4 microg/l), followed by Umba (median 2.7 microg/l), Zapolyarny (median 2.0 microg/l), Apatity (median 1.9 microg/l), Tromso (median 1.2 microg/l), and Sor-Varanger (median 0.6 microg/l). Regardless of geographical location, the Russian study groups all had a higher urinary-nickel average than those in Norway (p<0.001). With the exception of Nikel, neither the Russian nor the Norwegian urinary-nickel levels were associated with residence location near a Russian nickel refinery. We concluded that industrial nickel pollution alone could not explain the observed discrepancy between Norway and Russia; we also discuss other possible nickel exposure sources that may account for the high urinary levels found in Russia. Images Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 PMID:9681979

Precise tuning in platinum-nickel/nickel sulfide interface nanowires for synergistic hydrogen evolution catalysis

PubMed Central

Wang, Pengtang; Zhang, Xu; Zhang, Jin; Wan, Sheng; Guo, Shaojun; Lu, Gang; Yao, Jianlin; Huang, Xiaoqing

2017-01-01

Comprising abundant interfaces, multicomponent heterostructures can integrate distinct building blocks into single entities and yield exceptional functionalities enabled by the synergistic components. Here we report an efficient approach to construct one-dimensional metal/sulfide heterostructures by directly sulfuring highly composition-segregated platinum-nickel nanowires. The heterostructures possess a high density of interfaces between platinum-nickel and nickel sulfide components, which cooperate synergistically towards alkaline hydrogen evolution reaction. The platinum-nickel/nickel sulfide heterostructures can deliver a current density of 37.2 mA cm−2 at an overpotential of 70 mV, which is 9.7 times higher than that of commercial Pt/C. The heterostructures also offer enhanced stability revealed by long-term chronopotentiometry measurements. The present work highlights a potentially powerful interface-engineering strategy for designing multicomponent heterostructures with advanced performance in hydrogen evolution reaction and beyond. PMID:28239145

The Mean vs Life-Limiting Fatigue Response of a Ni-Base Superalloy, Part 1: Mechanisms (Preprint)

DTIC Science & Technology

2008-09-01

34’"L’\\" ~~·~~~:~~~?~i.. ~ ~I~~~.~.’ ,~.- .":_~ ••-:;’~.:-- 10JJITl 3 4 S 6 Grain diameter (",m) Figure 1: Microstructure of the INIOO...DATES COVERED (From - To) September 2008 Journal Article Preprint 4 . TITLE AND SUBTITLE THE MEAN VS LIFE-LIMITING FATIGUE RESPONSE OF A Ni-BASE...SUPERALLOY, PART 1: MECHANISMS (PREPRINT) 5a. CONTRACT NUMBER In-house 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 62102F 6 . AUTHOR(S

Ir-based refractory superalloys by pulse electric current sintering (PECS) process (II prealloyed powder)

NASA Astrophysics Data System (ADS)

Huang, C.; Yamabe-Mitarai, Y.; Harada, H.

2002-02-01

Five prealloyed powder samples prepared from binary Ir-based refractory superalloys were sintered at 1800 °C for 4 h by Pulse Electric Current Sintering (PECS). No metal loss was observed during sintering. The relative densities of the sintered specimens all exceeded 90% T.D. The best one was Ir-13% Hf with the density of 97.82% T.D. Phases detected in sintered samples were in accordance with the phase diagram as expected. Fractured surfaces were observed in two samples (Ir-13% Hf and Ir-15% Zr). Some improvements obtained by using prealloyed powders instead of elemental powders, which were investigated in the previous studies, were presented.

Creep Mechanisms of a Ni-Co-Based-Wrought Superalloy with Low Stacking Fault Energy

NASA Astrophysics Data System (ADS)

Tian, Chenggang; Xu, Ling; Cui, Chuanyong; Sun, Xiaofeng

2015-10-01

In order to study the influences of stress and temperature on the creep deformation mechanisms of a newly developed Ni-Co-based superalloy with low stacking fault energy, creep experiments were carried out under a stress range of 345 to 840 MPa and a temperature range of 923 K to 1088 K (650 °C to 815 °C). The mechanisms operated under the various creep conditions were identified and the reasons for their transformation were well discussed. A deformation mechanism map under different creep conditions was summarized, which provides a qualitative representation of the operative creep mechanisms as a function of stress and temperature.

Statistical study of ductility-dip cracking induced plastic deformation in polycrystalline laser 3D printed Ni-based superalloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Qian, Dan; Xue, Jiawei; Zhang, Anfeng

Ductility-dip cracking in Ni-based superalloy, resulting from heat treatment, is known to cause disastrous failure, but its mechanism is still not completely clear. A statistical study of the cracking behavior as a function of crystal orientation in a laser 3D-printed DL125L Ni-based superalloy polycrystal is investigated here using the synchrotron X-ray microdiffraction. The dislocation slip system in each of the forty crystal grains adjacent to the 300 μm long crack has been analyzed through Laue diffraction peak shapes. In all these grains, edge-type geometrically necessary dislocations (GNDs) dominate, and their dislocation line directions are almost parallel to the crack plane.more » Based on Schmid's law, the equivalent uniaxial tensile force direction is revealed normal to the trace of the crack. A qualitative mechanism is thus proposed. Thermal tensile stress perpendicular to the laser scanning direction is elevated due to a significant temperature gradient, and thus locations in the materials where the thermal stress exceeds the yield stress undergo plastic deformation mediated by GND activations. As the dislocations slip inside the crystal grains and pile up at the grain boundaries, local strain/stress keeps increasing, until the materials in these regions fail to sustain further deformation, leading to voids formation and cracks propagation.« less

Statistical study of ductility-dip cracking induced plastic deformation in polycrystalline laser 3D printed Ni-based superalloy

DOE PAGES

Qian, Dan; Xue, Jiawei; Zhang, Anfeng; ...

2017-06-06

Ductility-dip cracking in Ni-based superalloy, resulting from heat treatment, is known to cause disastrous failure, but its mechanism is still not completely clear. A statistical study of the cracking behavior as a function of crystal orientation in a laser 3D-printed DL125L Ni-based superalloy polycrystal is investigated here using the synchrotron X-ray microdiffraction. The dislocation slip system in each of the forty crystal grains adjacent to the 300 μm long crack has been analyzed through Laue diffraction peak shapes. In all these grains, edge-type geometrically necessary dislocations (GNDs) dominate, and their dislocation line directions are almost parallel to the crack plane.more » Based on Schmid's law, the equivalent uniaxial tensile force direction is revealed normal to the trace of the crack. A qualitative mechanism is thus proposed. Thermal tensile stress perpendicular to the laser scanning direction is elevated due to a significant temperature gradient, and thus locations in the materials where the thermal stress exceeds the yield stress undergo plastic deformation mediated by GND activations. As the dislocations slip inside the crystal grains and pile up at the grain boundaries, local strain/stress keeps increasing, until the materials in these regions fail to sustain further deformation, leading to voids formation and cracks propagation.« less

Advances in nickel hydrogen technology at Yardney Battery Division

NASA Technical Reports Server (NTRS)

Bentley, J. G.; Hall, A. M.

1987-01-01

The current major activites in nickel hydrogen technology being addressed at Yardney Battery Division are outlined. Five basic topics are covered: an update on life cycle testing of ManTech 50 AH NiH2 cells in the LEO regime; an overview of the Air Force/industry briefing; nickel electrode process upgrading; 4.5 inch cell development; and bipolar NiH2 battery development.

Nickel Ion Release from Three Types of Nickel-titanium-based Orthodontic Archwires in the As-received State and After Oral Simulation

PubMed Central

Ramazanzadeh, Barat Ali; Ahrari, Farzaneh; Sabzevari, Berahman; Habibi, Samaneh

2014-01-01

Background and aims. This study aimed to investigate release of nickel ion from three types of nickel-titanium-based wires in the as-received state and after immersion in a simulated oral environment. Materials and methods. Forty specimens from each of the single-strand NiTi (Rematitan "Lite"), multi-strand NiTi (SPEED Supercable) and Copper NiTi (Damon Copper NiTi) were selected. Twenty specimens from each type were used in the as-received state and the others were kept in deflected state at 37ºC for 2 months followed by autoclave sterilization. The as-received and recycled wire specimens were immersed in glass bottles containing 1.8 mL of artificial saliva for 28 days and the amount of nickel ion released into the electrolyte was determined using atomic absorption spectrophotometry. Results. The single-strand NiTi released the highest quantity of nickel ion in the as-received state and the multi-strand NiTi showed the highest ion release after oral simulation. The quantity of nickelion released from Damon Copper NiTi was the lowest in both conditions. Oral simulation followed by sterilization did not have a significant influence on nickel ion release from multi-strand NiTi and Damon Copper NiTi wires, but single-strand NiTi released statistically lower quantities of nickel ion after oral simulation. Conclusion. The multi-strand nature of Supercable did not enhance the potential of corrosion after immersion in the simulated oral environment. In vitro use of nickel-titanium-based archwires followed by sterilization did not significantly increase the amount of nickel ion released from these wires. PMID:25093049

Segregation-Assisted Plasticity in Ni-Based Superalloys

NASA Astrophysics Data System (ADS)

Barba, D.; Smith, T. M.; Miao, J.; Mills, M. J.; Reed, R. C.

2018-03-01

Correlative high-resolution transmission electron microscopy and energy-dispersive X-ray spectroscopy are used to study deformation-induced planar faults in the single-crystal superalloy MD2 crept at 800 °C and 650 MPa. Segregation of Cr and Co at microtwins, anti-phase boundaries (APB), and complex/superlattice extrinsic and intrinsic stacking faults (CESF/SESF and CISF/SISF) is confirmed and quantified. The extent of this is found to depend upon the fault type, being most pronounced for the APB. The CESF/SESF is studied in detail due to its role as a precursor of the microtwins causing the majority of plasticity under these conditions. Quantitative modeling is carried out to rationalize the findings; the experimental results are consistent with a greater predicted velocity for the lengthening of the CESF/SESF—compared with the other types of fault—and hence confirm its role in the diffusion-assisted plasticity needed for the microtwinning mechanism to be operative.

Cyclic oxidation behavior of some plasma-sprayed coatings in Na2SO4-60%V2O5 environment

NASA Astrophysics Data System (ADS)

Singh, Harpreet; Prakash, Satya; Puri, Devendra; Phase, D. M.

2006-12-01

Cyclic oxidation behavior of plasma-sprayed NiCrAlY, Ni-20Cr, Ni3Al, and Stellite-6 coatings was investigated in an aggressive environment of Na2SO4-60%V2O5 by thermogravimetric techniques for 50 cycles. These coatings were deposited on a Ni-base superalloy, namely Superni 600; 10Fe-15.5Cr-0.5Mn-0.2C-Bal Ni (wt.%). X-ray diffraction, scanning electron microscopy/energy dispersive x-ray (SEM/EDX), and electron probe microanalyzer (EPMA) techniques were used to analyze the oxidation products. The uncoated superalloy suffered accelerated oxidation in the form of intense spallation of its oxide scale. After deposition of the NiCrAlY coating, the superalloy showed a minimum mass gain, whereas after application of the Stellite-6 coating, a maximum mass gain was observed among the coatings studied. All of the coatings were found to be useful in reducing the spallation of the substrate superalloy. Moreover, the coatings were successful in maintaining continuous surface contact with the base superalloy during the cyclic oxidation. The phases revealed for the oxidized coatings were mainly the oxides of chromium and/or aluminum and the spinels containing nickel-chromium/cobalt-chromium/nickel-aluminum mixed oxides, which are reported to be protective against high-temperature oxidation/hot corrosion.

Effects of alloy composition on cyclic flame hot-corrosion attack of cast nickel-base superalloys at 900 deg C

NASA Technical Reports Server (NTRS)

Deadmore, D. L.

1984-01-01

The effects of Cr, Al, Ti, Mo, Ta, Nb, and W content on the hot corrosion of nickel base alloys were investigated. The alloys were tested in a Mach 0.3 flame with 0.5 ppmw sodium at a temperature of 900 C. One nondestructive and three destructive tests were conducted. The best corrosion resistance was achieved when the Cr content was 12 wt %. However, some lower-Cr-content alloys ( 10 wt%) exhibited reasonable resistance provided that the Al content alloys ( 10 wt %) exhibited reasonable resistance provided that the Al content was 2.5 wt % and the Ti content was Aa wt %. The effect of W, Ta, Mo, and Nb contents on the hot-corrosion resistance varied depending on the Al and Ti contents. Several commercial alloy compositions were also tested and the corrosion attack was measured. Predicted attack was calculated for these alloys from derived regression equations and was in reasonable agreement with that experimentally measured. The regression equations were derived from measurements made on alloys in a one-quarter replicate of a 2(7) statistical design alloy composition experiment. These regression equations represent a simple linear model and are only a very preliminary analysis of the data needed to provide insights into the experimental method.

Mechanical and Microstructure Study of Nickel-Based ODS Alloys Processed by Mechano-Chemical Bonding and Ball Milling

NASA Astrophysics Data System (ADS)

Amare, Belachew N.

Due to the need to increase the efficiency of modern power plants, land-based gas turbines are designed to operate at high temperature creating harsh environments for structural materials. The elevated turbine inlet temperature directly affects the materials at the hottest sections, which includes combustion chamber, blades, and vanes. Therefore, the hottest sections should satisfy a number of material requirements such as high creep strength, ductility at low temperature, high temperature oxidation and corrosion resistance. Such requirements are nowadays satisfied by implementing superalloys coated by high temperature thermal barrier coating (TBC) systems to protect from high operating temperature required to obtain an increased efficiency. Oxide dispersive strengthened (ODS) alloys are being considered due to their high temperature creep strength, good oxidation and corrosion resistance for high temperature applications in advanced power plants. These alloys operating at high temperature are subjected to different loading systems such as thermal, mechanical, and thermo-mechanical combined loads at operation. Thus, it is critical to study the high temperature mechanical and microstructure properties of such alloys for their structural integrity. The primary objective of this research work is to investigate the mechanical and microstructure properties of nickel-based ODS alloys produced by combined mechano-chemical bonding (MCB) and ball milling subjected to high temperature oxidation, which are expected to be applied for high temperature turbine coating with micro-channel cooling system. Stiffness response and microstructure evaluation of such alloy systems was studied along with their oxidation mechanism and structural integrity through thermal cyclic exposure. Another objective is to analyze the heat transfer of ODS alloy coatings with micro-channel cooling system using finite element analysis (FEA) to determine their feasibility as a stand-alone structural

Corrosion behavior of pre-oxidized HR-224 superalloy in supercritical water environment at 700 °C

NASA Astrophysics Data System (ADS)

Liu, Yu-Chen; Chen, Shih-Ming; Ouyang, Fan-Yi; Kai, Ji-Jung

2018-07-01

Corrosion of cladding materials in supercritical water (SCW) environment is a key reliability issue for the safety of nuclear power plant. In this study, we propose to use the pre-oxidized treatment to provide better corrosion resistance of cladding materials in the SCW environment. The nickel-based superalloy HR-224 was first pre-oxidized in flowing air at 982 °C for 100 h to establish a continuous and dense scales and then exposed in the SCW environment with high oxygen content (8.3 ppm) at 700 °C and 24.8 MPa for cyclic oxidation testing up to 1300 h. The pre-oxidized samples exhibit better corrosion resistance than as-received samples in the SCW environment. After pre-oxidizing process, triple scales, Ni(Cr, Fe)2O4 spinel/Cr2O3/α-Al2O3 were observed, and the growth of inner α-Al2O3 layer is predominant in the SCW environment. The α-Al2O3 layer in pre-oxidized samples was found to effectively decrease outward migration of metal ions in Alloy HR-224 and thus provides better corrosion resistance than as-received samples in SCW environment.

Cyclic Spin Testing of Superalloy Disks With a Dual Grain Microstructure

NASA Technical Reports Server (NTRS)

Gayda, John; Kantzos, Pete

2005-01-01

An aggressive cyclic spin test program was run to verify the reliability of superalloy disks with a dual grain structure, fine grain bore and coarse grain rim, utilizing a disk design with web holes bisecting the grain size transition zone. Results of these tests were compared with conventional disks with uniform grain structures. Analysis of the test results indicated the cyclic performance of disks with a dual grain structure could be estimated to a level of accuracy which does not appear to prohibit the use of this technology in advanced gas turbine engines, although further refinement of lifing methodology is clearly warranted.

Exploratory screening tests of several alloys and coatings for automobile thermal reactors

NASA Technical Reports Server (NTRS)

Oldrieve, R. E.

1971-01-01

A total of 23 materials (including uncoated ferritic and austenitic iron-base alloys, uncoated nickel and cobalt-base superalloys, and several different coatings on AISI 304 stainless steel) were screened as test coupons on a rack in an automobile thermal reactor. Test exposures were generally 51 hours including 142 thermal cycles of 10 minutes at 1010 + or - 30 C test coupon temperature and 7-minutes cool-down to about 510 C. Materials that exhibited corrosion resistance better than that of Hastelloy X include: a ferritic iron alloy with 6 weight percent aluminum; three nickel-base superalloys; two diffused-aluminum coatings on AISI 304; and a Ni-Cr slurry-sprayed coating on AISI 304. Preliminary comparison is made on the performance of the directly impinged coupons and a reactor core of the same material.

Effects of Jet Pressure on the Ground Surface Quality and CBN Wheel Wear in Grinding AISI 690 Nickel-Based Superalloy

NASA Astrophysics Data System (ADS)

Guitouni, Ahmed; Chaieb, Iheb; Rhouma, Amir Ben; Fredj, Nabil Ben

2016-11-01

Fluid application in grinding is getting attention as higher stock removal rates, higher surface integrity and longer wheel life are required. It is necessary to define proper conditions of application for meeting high productivity goals by lowering the specific grinding energy and reducing the temperature of the contact zone. The present study investigated the capacity of the jet pressure of a spot nozzle to improve the wear of a CBN wheel when grinding the AISI 690 superalloy. Grinding experiments were conducted with an emulsion-type cooling fluid delivered at pressure ranging from 0.1 to 4 MPa. Results show that the maximum stock removal, reached at 4 MPa, is 5 times the stock removal obtained at 0.1 MPa, while the grinding ratio at 4 MPa is 8 times that at 0.1 MPa, and there is a critical pressure ( P c) around 1.5 MPa corresponding to the minimum specific grinding energy. Scanning electron microscopy of the grain tips showed that the wear mechanism shifts from breaking and dislodgment at low jet pressure to micro-fracture resulting in continuous self-sharpening of the abrasive grains. By lubricating at jet pressure close to P c, there is less thermal damage due to plowing and sliding and the resulting lower loading of the abrasive grains favors the micro-fracture of grains and thus a longer wheel life.

Dispersion Strengthening.

DTIC Science & Technology

1987-07-27

June 1979. 22. p - V S~* ~~ " 17. " Strengthening Mechanisms in Martensitic Steels ", Peking University Institute for Iron and Steel Technology...directed towards studying the strengthening behavior of nickel-base superalloys, the strengthening behavior of ferrous martensite , and the kinetics of...coherency strain is not a dominant strengthening mechanism in nickel-base super- alloys with low volume fractions of -y The important conclusions

Low expansion superalloy with improved toughness

DOEpatents

Smith, Darrell F.; Stein, Larry I.; Hwang, Il S.

1995-01-01

A high strength, low coefficient of thermal expansion superalloy exhibiting improved toughness over a broad temperature range down to about 4.degree. K. The composition is adapted for use with wrought superconducting sheathing.

Low expansion superalloy with improved toughness

DOEpatents

Smith, D.F.; Stein, L.I.; Hwang, I.S.

1995-06-20

A high strength, low coefficient of thermal expansion superalloy exhibiting improved toughness over a broad temperature range down to about 4 K is disclosed. The composition is adapted for use with wrought superconducting sheathing.

Nickel extraction from nickel matte

NASA Astrophysics Data System (ADS)

Subagja, R.

2018-01-01

In present work, the results of research activities to make nickel metal from nickel matte are presented. The research activities were covering a) nickel matte characterization using Inductively Couple plasma (ICP), Electron Probe Micro Analyzer (EPMA) and X-Ray Diffraction (XRD), b) nickel matte dissolution process to dissolve nickel from nickel matte into the spent electrolyte solutions that contains hydrochloric acid, c) purification of nickel chloride leach solution by copper cementation process to remove copper using nickel matte, selective precipitation process to remove iron, solvent extraction using Tri normal octyl amine to separate cobalt from nickel chloride solutions and d) Nickel electro winning process to precipitate nickel into the cathode surface from purified nickel chloride solution by using direct current. The research activities created 99, 72 % pure nickel metal as the final product of the process.

Superalloy resources: Supply and availability

NASA Technical Reports Server (NTRS)

Stephens, Joseph R.

1987-01-01

Over the past several decades there have been shortages of strategic materials because of our near total import dependence on such metals as chromium, cobalt, and tantalum. In response to the continued vulnerability of U.S. superalloy producers to disruptions in resource supplies, NASA has undertaken a program to address alternatives to the super-alloys containing significant quantities of the strategic materials such as chromium, cobalt, niobium, and tantalum. The research program called Conservation of Strategic Aerospace Materials (COSAM) focuses on substitution, processing, and alternate materials to achieve its goals. In addition to NASA Lewis Research Center, universities and industry play an important role in the COSAM Program. This paper defines what is meant by strategic materials in the aerospace community, presents a strategic materials index, and reviews the resource supply and availability picture from the U.S. point of view. In addition, research results from the COSAM Program are highlighted and future directions for the use of low strategic material alloys or alternate materials are discussed.

Synthesis of bacteria promoted reduced graphene oxide-nickel sulfide networks for advanced supercapacitors.

PubMed

Zhang, Haiming; Yu, Xinzhi; Guo, Di; Qu, Baihua; Zhang, Ming; Li, Qiuhong; Wang, Taihong

2013-08-14

Supercapacitors with potential high power are useful and have attracted much attention recently. Graphene-based composites have been demonstrated to be promising electrode materials for supercapacitors with enhanced properties. To improve the performance of graphene-based composites further and realize their synthesis with large scale, we report a green approach to synthesize bacteria-reduced graphene oxide-nickel sulfide (BGNS) networks. By using Bacillus subtilis as spacers, we deposited reduced graphene oxide/Ni3S2 nanoparticle composites with submillimeter pores directly onto substrate by a binder-free electrostatic spray approach to form BGNS networks. Their electrochemical capacitor performance was evaluated. Compared with stacked reduced graphene oxide-nickel sulfide (GNS) prepared without the aid of bacteria, BGNS with unique nm-μm structure exhibited a higher specific capacitance of about 1424 F g(-1) at a current density of 0.75 A g(-1). About 67.5% of the capacitance was retained as the current density increased from 0.75 to 15 A g(-1). At a current density of 75 A g(-1), a specific capacitance of 406 F g(-1) could still remain. The results indicate that the reduced graphene oxide-nickel sulfide network promoted by bacteria is a promising electrode material for supercapacitors.

High temperature oxidation behavior of gamma-nickel+gamma'-nickel aluminum alloys and coatings modified with platinum and reactive elements

NASA Astrophysics Data System (ADS)

Mu, Nan

Materials for high-pressure turbine blades must be able to operate in the high-temperature gases (above 1000°C) emerging from the combustion chamber. Accordingly, the development of nickel-based superalloys has been constantly motivated by the need to have improved engine efficiency, reliability and service lifetime under the harsh conditions imposed by the turbine environment. However, the melting point of nickel (1455°C) provides a natural ceiling for the temperature capability of nickel-based superalloys. Thus, surface-engineered turbine components with modified diffusion coatings and overlay coatings are used. Theses coatings are capable of forming a compact and adherent oxide scale, which greatly impedes the further transport of reactants between the high-temperature gases and the underlying metal and thus reducing attack by the atmosphere. Typically, these coatings contain beta-NiAl as a principal constituent phase in order to have sufficient aluminum content to form an Al2O3 scale at elevated temperatures. The drawbacks to the currently-used beta-based coatings, such as phase instabilities, associated stresses induced by such phase instabilities, and extensive coating/substrate interdiffusion, are major motivations in this study to seek next-generation coatings. The high-temperature oxidation resistance of novel Pt+Hf-modified gamma-Ni+gamma'-Ni 3Al-based alloys and coatings were investigated in this study. Both early-stage and 4-days isothermal oxidation behavior of single-phase gamma-Ni and gamma'-Ni3Al alloys were assessed by examining the weight changes, oxide-scale structures, and elemental concentration profiles through the scales and subsurface alloy regions. It was found that Pt promotes Al 2O3 formation by suppressing the NiO growth on both gamma-Ni and gamma'-Ni3Al single-phase alloys. This effect increases with increasing Pt content. Moreover, Pt exhibits this effect even at lower temperatures (˜970°C) in the very early stage of oxidation. It

Ni-base superalloy powder-processed porous layer for gas cooling in extreme environments

DOE PAGES

White, Emma M. H.; Heidloff, Andrew J.; Byrd, David J.; ...

2016-05-26

Extreme high temperature conditions demand novel solutions for hot gas filters and coolant access architectures, i.e., porous layers on exposed components. These high temperatures, for example in current turbine engines, are at or exceeding current material limits for high temperature oxidation/corrosion, creep resistance, and, even, melting temperature. Thus novel blade designs allowing greater heat removal are required to maintain airfoil temperatures below melting and/ or rapid creep deformation limits. Gas atomized Ni-base superalloy powders were partially sintered into porous layers to allow full-surface, transpirational cooling of the surface of airfoils. Furthermore, these powder-processed porous layers were fully characterized for surface,more » morphology, cross-sectional microstructure, and mechanical strength characteristics. A sintering model based on pure Ni surface diffusion correlated well with the experimental results and allowed reasonable control over the partial sintering process to obtain a specified level of porosity within the porous layer.« less

Ni-base superalloy powder-processed porous layer for gas cooling in extreme environments

DOE Office of Scientific and Technical Information (OSTI.GOV)

White, Emma M. H.; Heidloff, Andrew J.; Byrd, David J.

Extreme high temperature conditions demand novel solutions for hot gas filters and coolant access architectures, i.e., porous layers on exposed components. These high temperatures, for example in current turbine engines, are at or exceeding current material limits for high temperature oxidation/corrosion, creep resistance, and, even, melting temperature. Thus novel blade designs allowing greater heat removal are required to maintain airfoil temperatures below melting and/ or rapid creep deformation limits. Gas atomized Ni-base superalloy powders were partially sintered into porous layers to allow full-surface, transpirational cooling of the surface of airfoils. Furthermore, these powder-processed porous layers were fully characterized for surface,more » morphology, cross-sectional microstructure, and mechanical strength characteristics. A sintering model based on pure Ni surface diffusion correlated well with the experimental results and allowed reasonable control over the partial sintering process to obtain a specified level of porosity within the porous layer.« less

Study on Plastic Deformation Characteristics of Shot Peening of Ni-Based Superalloy GH4079

NASA Astrophysics Data System (ADS)

Zhong, L. Q.; Liang, Y. L.; Hu, H.

2017-09-01

In this paper, the X-ray stress diffractometer, surface roughness tester, field emission scanning electron microscope(SEM), dynamic ultra-small microhardness tester were used to measure the surface residual stress and roughness, topography and surface hardness changes of GH4079 superalloy, which was processed by metallographic grinding, turning, metallographic grinding +shot peening and turning + shot peening. Analysized the effects of shot peening parameters on shot peening plastic deformation features; and the effects of the surface state before shot peening on shot peening plastic deformation characteristics. Results show that: the surface residual compressive stress, surface roughness and surface hardness of GH4079 superalloy were increased by shot peening, in addition, the increment of the surface residual compressive stress, surface roughness and surface hardness induced by shot peening increased with increasing shot peening intensity, shot peening time, shot peening pressure and shot hardness, but harden layer depth was not affected considerably. The more plastic deformation degree of before shot peening surface state, the less increment of the surface residual compressive stress, surface roughness and surface hardness induced by shot peening.

Secondary arm coarsening and microsegregation in superalloy PWA-1480 single crystals: Effect of low gravity

NASA Technical Reports Server (NTRS)

Vijayakumar, M.; Tewari, S. N.; Lee, J. E.; Curreri, P. A.

1990-01-01

Single crystal specimens of nickel base superalloy PWA-1480 were directionally solidified on ground and during low gravity (20 sec) and high gravity (90 sec) parabolic maneuver of KC-135 aircraft. Thermal profiles were measured during solidification by two in-situ thermocouples positioned along the sample length. The samples were quenched during either high or low gravity cycles so as to freeze the structures of the mushy zone developing under different gravity levels. Microsegregation was measured by examining the solutal profiles on several transverse cross-sections across primary dendrites along their length in the quenched mushy zone. Effect of gravity level on secondary arm coarsening kinetics and microsegregation have been investigated. The results indicate that there is no appreciable difference in the microsegregation and coarsening kinetics behavior in the specimens grown under high or low gravity. This suggests that short duration changes in gravity/levels (0.02 to 1.7 g) do not influence convection in the interdendritic region. Examination of the role of natural convection, in the melt near the primary dendrite tips, on secondary arm spacings requires low gravity periods longer than presently available on KC-135. Secondary arm coarsening kinetics show a reasonable fit with the predictions from a simple analytical model proposed by Kirkwood for a binary alloy.

Elevated Temperature Properties of Titanium Carbide Base Ceramals Containing Nickel or Iron

NASA Technical Reports Server (NTRS)

Cooper, A L; Colteryahn, L E

1951-01-01

Elevated-temperature properties of titanium carbide base ceramals containing nickel or iron were determined in oxidation, modulus of rupture, tensile strength, and thermal-shock resistance. These materials followed the general growth law and exhibited two stages in oxidation. The following tensile strengths were found at 2000 degrees F: 13.3 weight percent nickel, 16, 150 pounds per square inch; 11.8 weight percent iron, 12,500 pounds per square inch; unalloyed titanium carbide, 16,450 pounds per square inch. Nickel or iron additions to titanium carbide improved the thermal-shock resistance, nickel more. The path of fracture in tensile and thermal-shock specimens was found to progress approximately 50 percent intergranularly and 50 percent transgranularly.

Removing nickel from nickel-coated carbon fibers

NASA Astrophysics Data System (ADS)

Hardianto, A.; Hertleer, C.; De Mey, G.; Van Langenhove, L.

2017-10-01

Conductive fibers/yarns are one of the most important materials for smart textiles because of their electrically conductive functionality combined with flexibility and light weight. They can be applied in many fields such as the medical sector, electronics, sensors and even as thermoelectric generators. Temperature sensors, for example, can be made using the thermocouple or thermopile principle which usually uses two different metal wires that can produce a temperature-dependent voltage. However, if metal wires are inserted into a textile structure, they will decrease the flexibility properties of the textile product. Nickel-coated Carbon Fiber (NiCF), a conductive textile yarn, has a potential use as a textile-based thermopile if we can create an alternating region of carbon and nickel along the fiber which in turn it can be used for substituting the metallic thermopile. The idea was to remove nickel from NiCF in order to obtain a yarn that contains alternating zones of carbon and nickel. Due to no literature reporting on how to remove nickel from NiCF, in this paper we investigated some chemicals to remove nickel from NiCF.

Role of back stress in the creep behavior of particle strengthened alloys

NASA Technical Reports Server (NTRS)

Purushothaman, S.; Tien, J. K.

1978-01-01

Recent developments in the interpolation of high-temperature steady-state creep results have introduced the concept that the stress dependence of the creep rate should be in terms of the effective stress referred to as the applied stress minus a back stress. This paper reports on back stresses taken from data on a gamma-prime-strengthened wrought nickel-base superalloy, an oxide dispersion-strengthened ODS nickel-base solid solution alloy, and an ODS nickel-base superalloy. The effect of air versus vacuum environments and the effect of dynamic changes in the strengthening microstructures on the magnitude of the back stress are assessed. The role of modulus normalization and the back stress correction in determining the true creep activation energy are examined. It is shown that the high values of the apparent stress exponent 'n' of the steady-state creep equation can be easily explained through a relationship between n, the true stress exponent of steady-state creep, and the stress which when subtracted from the applied stress results in the effective driving stress acting on the mobile dislocations during creep.

Advanced turbine study

NASA Technical Reports Server (NTRS)

Castro, J. H.

1985-01-01

The feasibility of an advanced convective cooling concept applied to rocket turbine airfoils which operate in a high pressure hydrogen and methane environment was investigated. The concept consists of a central structural member in which grooves are machined. The grooves are temporarily filled with a removable filler and the entire airfoil is covered with a layer of electroformed nickel, or nickel base alloy. After removal of the filler, the low thermal resistance of the nickel closure causes the wall temperature to be reduced by heat transfer to the coolant. The program is divided in the following tasks: (1) turbine performance appraisal; (2) coolant geometry evaluation; (3) test hardware design and analysis; and (4) test airfoil fabrication.

Wear-dependent specific coefficients in a mechanistic model for turning of nickel-based superalloy with ceramic tools

NASA Astrophysics Data System (ADS)

López de Lacalle, Luis Norberto; Urbicain Pelayo, Gorka; Fernández-Valdivielso, Asier; Alvarez, Alvaro; González, Haizea

2017-09-01

Difficult to cut materials such as nickel and titanium alloys are used in the aeronautical industry, the former alloys due to its heat-resistant behavior and the latter for the low weight - high strength ratio. Ceramic tools made out alumina with reinforce SiC whiskers are a choice in turning for roughing and semifinishing workpiece stages. Wear rate is high in the machining of these alloys, and consequently cutting forces tends to increase along one operation. This paper establishes the cutting force relation between work-piece and tool in the turning of such difficult-to-cut alloys by means of a mechanistic cutting force model that considers the tool wear effect. The cutting force model demonstrates the force sensitivity to the cutting engagement parameters (ap, f) when using ceramic inserts and wear is considered. Wear is introduced through a cutting time factor, being useful in real conditions taking into account that wear quickly appears in alloys machining. A good accuracy in the cutting force model coefficients is the key issue for an accurate prediction of turning forces, which could be used as criteria for tool replacement or as input for chatter or other models.

Fiber reinforced superalloys

NASA Technical Reports Server (NTRS)

Petrasek, Donald W.; Signorelli, Robert A.; Caulfield, Thomas; Tien, John K.

1987-01-01

Improved performance of heat engines is largely dependent upon maximum cycle temperatures. Tungsten fiber reinforced superalloys (TFRS) are the first of a family of high temperature composites that offer the potential for significantly raising hot component operating temperatures and thus leading to improved heat engine performance. This status review of TFRS research emphasizes the promising property data developed to date, the status of TFRS composite airfoil fabrication technology, and the areas requiring more attention to assure their applicability to hot section components of aircraft gas turbine engines.

Precipitation hardening austenitic superalloys

DOEpatents

Korenko, Michael K.

1985-01-01

Precipitation hardening, austenitic type superalloys are described. These alloys contain 0.5 to 1.5 weight percent silicon in combination with about 0.05 to 0.5 weight percent of a post irradiation ductility enhancing agent selected from the group of hafnium, yttrium, lanthanum and scandium, alone or in combination with each other. In addition, when hafnium or yttrium are selected, reductions in irradiation induced swelling have been noted.

An overview of the measurements of thermophysical properties and some results on molten superalloys and semiconductors

NASA Technical Reports Server (NTRS)

Taylor, R. E.

1993-01-01

This presentation consists of two parts: comments on the results of measurements on thermophysical properties based on the paper, 'Things Mother Never Taught Me (About Thermophysical Properties of Solids)' and results of thermophysical property measurements on selected solid and molten semiconductors and a proprietary superalloy. The first part may be considered as a tutorial for those involved in using or procuring thermophysical property data. The second part is presented as illustrations of what has been accomplished on molten materials at the Thermophysical Properties Research Laboratory (TPRL). The materials include Ge, PbTe, PbSnTe, HgCdTe and a superalloy.

Reestablishing Strategic and Critical Material Security in the Department of Defense

DTIC Science & Technology

2011-05-11

Nickel >700% Tungsten 300% Titanium 600% Cobalt 325% Germanium 300% Chromium 500% Molybdenum 500% Indium 300% Manganese 350% Rhenium > 1000% Peak...CHAIN LEADERSHIP New Mission Example • Currently working with Tinker Air Force Base on a rhenium availability issue – Rhenium is a super alloy used in...acquisitions to assure industrial base capability – Titanium – Rare Earth Elements – Germanium – Rhenium / nickel super-alloys – Other materials as supply chain

Multiaxial Fatigue Life Prediction Based on Nonlinear Continuum Damage Mechanics and Critical Plane Method

NASA Astrophysics Data System (ADS)

Wu, Z. R.; Li, X.; Fang, L.; Song, Y. D.

2018-04-01

A new multiaxial fatigue life prediction model has been proposed in this paper. The concepts of nonlinear continuum damage mechanics and critical plane criteria were incorporated in the proposed model. The shear strain-based damage control parameter was chosen to account for multiaxial fatigue damage under constant amplitude loading. Fatigue tests were conducted on nickel-based superalloy GH4169 tubular specimens at the temperature of 400 °C under proportional and nonproportional loading. The proposed method was checked against the multiaxial fatigue test data of GH4169. Most of prediction results are within a factor of two scatter band of the test results.

Near-Threshold Fatigue Crack Growth Behavior of Fine-Grain Nickel-Based Alloys

NASA Technical Reports Server (NTRS)

Newman, John A.; Piascik, Robert S.

2003-01-01

Constant-Kmax fatigue crack growth tests were performed on two finegrain nickel-base alloys Inconel 718 (DA) and Ren 95 to determine if these alloys exhibit near-threshold time-dependent crack growth behavior observed for fine-grain aluminum alloys in room-temperature laboratory air. Test results showed that increases in K(sub max) values resulted in increased crack growth rates, but no evidence of time-dependent crack growth was observed for either nickel-base alloy at room temperature.

Recrystallization characteristics of oxide dispersion strengthened nickel-base alloys

NASA Technical Reports Server (NTRS)

Hotzler, R. K.; Glasgow, T. K.

1980-01-01

Electron microscopy was employed to study the process of recrystallization in two oxide dispersion strengthened (ODS) mechanically alloyed nickel-base alloys, MA 754 and MA 6000E. MA 754 contained both fine, uniformly dispersed particles and coarser oxides aligned along the working direction. Hot rolled MA 754 had a grain size of 0.5 microns and high dislocation densities. After partial primary recrystallization, the fine grains transformed to large elongated grains via secondary (or abnormal) grain growth. Extruded and rolled MA 6000E contained equiaxed grains of 0.2 micron diameter. Primary recrystallization occurring during working eliminated virtually all dislocations. Conversion from fine to coarse grains was triggered by gamma prime dissolution; this was also a process of secondary or abnormal grain growth. Comparisons were made to conventional and oxide dispersion strengthened nickel-base alloys.

MEMS-based wide-bandwidth electromagnetic energy harvester with electroplated nickel structure

NASA Astrophysics Data System (ADS)

Sun, Shi; Dai, Xuhan; Sun, Yunna; Xiang, Xiaojian; Ding, Guifu; Zhao, Xiaolin

2017-11-01

A novel nickel-based nonlinear electromagnetic energy harvester has been designed, fabricated, and characterized in this work. Electroplated nickel is very suitable for a stretching-based mechanism to broaden the bandwidth due to its good process and mechanical properties. A strong hardening nonlinearity is induced due to the large deformation of the thin nickel based guided-beam structure. Combining the merits of both the mechanical properties and guided-beam structure, the energy harvester shows good bandwidth performance. It is found that increasing the thickness of the central platform could guarantee nonlinearity. Static and dynamic models of the energy harvester are simulated and validated. Test results show that the energy harvester has good repeatability without any destruction under a large deformation condition. At the acceleration of 0.5 g, comparative large bandwidths of 129 and 59 Hz are obtained for displacement and RMS output voltage, respectively. Power output of 3.4 µW and normalized power density of 125.92 µW cm-3 g-2 are achieved with the load resistance of 38 Ω.

The elemental move characteristic of nickel-based alloy in molten salt corrosion by using nuclear microprobe

NASA Astrophysics Data System (ADS)

Lei, Qiantao; Liu, Ke; Gao, Jie; Li, Xiaolin; Shen, Hao; Li, Yan

2017-08-01

Nickel-based alloys as candidate materials for Thorium Molten Salt Reactor (TMSR), need to be used under high temperature in molten salt environment. In order to ensure the safety of the reactor running, it is necessary to study the elemental move characteristic of nickel-based alloys in the high temperature molten salts. In this work, the scanning nuclear microprobe at Fudan University was applied to study the elemental move. The Nickel-based alloy samples were corroded by molten salt at different temperatures. The element concentrations in the Nickel-based alloys samples were determined by the scanning nuclear microprobe. Micro-PIXE results showed that the element concentrations changed from the interior to the exterior of the alloy samples after the corrosion.

Deep eutectic solvent approach towards nickel/nickel nitride nanocomposites

DOE PAGES

Gage, Samuel H.; Ruddy, Daniel A.; Pylypenko, Svitlana; ...

2016-12-15

Nickel nitride is an attractive material for a broad range of applications including catalysis. However preparations and especially those targeting nanoscale particles remain a major challenge. Herein, we report a wet-chemical approach to produce nickel/nickel nitride nanocomposites using deep eutectic solvents. A choline chloride/urea deep eutectic solvent was used as a reaction medium to form gels containing nickel acetate tetrahydrate. Heat treatment of the gel in inert atmosphere forms nanoparticles embedded within a nitrogen-doped carbon matrix. Thermogravimetric analysis (TGA) and differential thermal analysis (DTA) were used to understand the decomposition profile of the precursors and to select pyrolysis temperatures locatedmore » in regions of thermal stability. X-ray diffraction (XRD) confirmed the presence of metallic nickel, whereas X-ray photoelectron spectroscopy (XPS) suggested the existence of a nickel nitride surface layer. According to transmission electron microscopy (TEM) analysis these mixed phase, possibly core-shell type nanoparticles, have very defined facets. Furthermore, these materials represent a unique opportunity to tune catalytic properties of nickel-based catalysts through control of their composition, surface structure, and morphology; in addition to employing potential benefits of a nitrogen-doped carbon support.« less

Electrospark Deposition for Depot- and Field-Level Component Repair and Replacement of Hard Chromium Plating

DTIC Science & Technology

2008-02-01

with an ASAP proprietary process. Corrosion applications frequently are addressed with iron- aluminide and nickel alloys such as Inconel 625 alloy...IN625) and Hastelloy C-22. Wear applications commonly treated with ESD include cutting edges of chipper knives, saw teeth, and mower blades ; wear...Applications for ESD repair include components of steel, stainless steel, nickel- and cobalt-based superalloys, aluminum, Monel, titanium , and magnesium

Microstructure-sensitive Crystal Viscoplasticity for Ni-base Superalloys Targeting Long-term Creep-Fatigue Interaction Modeling

DOE Office of Scientific and Technical Information (OSTI.GOV)

Neu, Richard W.

The aim of this project is to develop a microstructure-sensitive crystal viscoplasticity (CVP) model for single-crystal Ni-base superalloys to model the behavior of the material and components in the hot gas path sections of industrial gas turbines (IGT). Microstructure degradation associated with aging critical to predicting long-term creep-fatigue interactions will be embedded into the model through the γ' precipitate morphology evolution by coupling the coarsening drivers and kinetics into the constitutive equations of the CVP model. Model parameters will be determined using new experimental protocols that involve systematically artificially aging the alloy under different stress conditions to determine the relationshipmore » between the size and morphology g' precipitates on the creep and thermomechanical fatigue response.« less

Microstructure-sensitive Crystal Viscoelasticity for Ni-base Superalloys Targeting Long-term Creep-Fatigue Interaction Modeling

DOE Office of Scientific and Technical Information (OSTI.GOV)

Neu, Richard W

The aim of this project is to develop a microstructure-sensitive crystal viscoplasticity (CVP) model for single-crystal Ni-base superalloys to model the behavior of the material and components in the hot gas path sections of industrial gas turbines (IGT). Microstructure degradation associated with aging critical to predicting long-term creep-fatigue interactions will be embedded into the model through the γ' precipitate morphology evolution by coupling the coarsening drivers and kinetics into the constitutive equations of the CVP model. Model parameters will be determined using new experimental protocols that involve systematically artificially aging the alloy under different stress conditions to determine the relationshipmore » between the size and morphology g' precipitates on the creep and thermomechanical fatigue response.« less

Advanced nickel-hydrogen cell configuration study

NASA Technical Reports Server (NTRS)

Adler, E.; Perez, F.

1984-01-01

Three nickel hydrogen battery designs, individual pressure vessel (IPV), common pressure vessel (CPV), and a bipolar battery module were studied. Weight, system complexity and cost were compared for a satellite operating in a 6 hour, 5600 nautical mile orbit. The required energy storage is 52 kWh. A 25% improvement in specific energy is observed by employing a bipolar battery versus a battery comprised of hundreds of IPV's. Further weight benefits are realized by the development of light weight technologies in the bipolar design.

Morphological changes of gamma prime precipitates in nickel-base superalloy single crystals. Ph.D. Thesis - Case Western Reserve Univ., May 1984

NASA Technical Reports Server (NTRS)

Mackay, R. A.

1984-01-01

Changes in the morphology of the gamma prime precipitate were examined during tensile creep at temperatures between 927 and 1038 C in 001-oriented single crystals of a Ni-Al-Mo-Ta superalloy. In this alloy, which has a large negative misfit of -0.80%, the gamma prime particles link together during creep to form platelets, or rafts, which are aligned with their broad faces perpendicular to the applied tensile axis. The dimensions of the gamma and gamma prime phases were measured as directional coarsening developed in an attempt to trace the changing morphology under various stress levels. In addition, the effects of initial microstructure, as well as slight compositional variations, were related to raft development and creep properties. The results showed that directional coarsening of gamma prime began during primary creep, and under certain conditions, continued to develop after the onset of steady-state creep. The length of the rafts increased linearly with time up to a plateau region. The thickness of the rafts, however, remained equal to the initial gamma prime size at least up through the onset of tertiary creep; this is a clear indication of the stability of the finely-spaced gamma-gamma prime lamellar structure. It was found that the single crystals with the finest gamma prime size exhibited the longest creep lives, because the resultant rafted structure had a larger number of gamma-gamma prime interfaces per unit volume of material.

Microstructural study of the nickel-base alloy WAZ-20 using qualitative and quantitative electron optical techniques

NASA Technical Reports Server (NTRS)

Young, S. G.

1973-01-01

The NASA nickel-base alloy WAZ-20 was analyzed by advanced metallographic techniques to qualitatively and quantitatively characterize its phases and stability. The as-cast alloy contained primary gamma-prime, a coarse gamma-gamma prime eutectic, a gamma-fine gamma prime matrix, and MC carbides. A specimen aged at 870 C for 1000 hours contained these same constituents and a few widely scattered high W particles. No detrimental phases (such as sigma or mu) were observed. Scanning electron microscope, light metallography, and replica electron microscope methods are compared. The value of quantitative electron microprobe techniques such as spot and area analysis is demonstrated.

High gas velocity oxidation and hot corrosion testing of oxide dispersion-strengthened nickel-base alloys