Comparative hot corrosion studies of EB-PVD and plasma sprayed coatings*

The use of directly fired heat engines, i. e. diesel and gas turbine engines, is likely to grow in the future. However, economic requirements will necessitate the development of highly efficient engines that operate at high temperatures and utilize low-grade fuels. An increase of combustion gas temperature and the utilization of low-grade fuels contaminated with, amongst others, sulphur and vanadium, may be accomplished by careful selection of the materials, e.g. by applying corrosion-resistant coatings on heatresistant alloys. The main purpose of the present work has been to test various coatingsubstrate combinations in a highly corrosive environment. The comparison of various coating techniques, e.g. electron beam physical vapour deposition (EB-PVD), air plasma spraying (APS), and low pressure plasma spraying/vacuum plasma spraying (LPPS/VPS), has been emphasized.     

The evaluation of the effects of control factors on surface roughness in the drilling of Waspaloy superalloy

In this study, the effects of cutting tool type (Ct), cutting speed (Vc), feed rate (f) and drill bit angle (A) on the average surface roughness (Ra) were investigated in the drilling of Waspaloy superalloy with coated and uncoated solid carbide drills. Experimental studies were performed in the orthogonal array of L18 (2¹ × 3³) by using Taguchi method. A second order predictive equation was developed with Linear Regression Analysis and coefficient of correlation for Ra calculated as R² = 96.9%. The most effective parameters on Ra were determined as A, f, Vc and Ct with 49.44%, 15.0%, 14.45% and 13.47% contribution ratios, respectively. Ra surface roughness values increased with the increasing tool wear. In this study, the chip formation and tool wear were also evaluated. Three types chip formation such as spiral chip, string chip and short chip were observed in the drilling of Waspaloy with solid carbide drills.     

服役后Waspaloy合金的组织及裂纹扩展行为

通过组织分析、裂纹扩展速率试验以及断口形貌分析等手段,研究了服役后Waspaloy合金的微观组织及裂纹扩展行为。进而通过热处理改变了合金的组织状态,比较了不同组织状态下合金的裂纹扩展速率。结果表明:经服役后Waspaloy合金的显微组织没有出现明显恶化,但其裂纹扩展速率显著升高;经两种热处理后合金的裂纹扩展速率都明显降低。     

烟气轮机涡轮盘高温合金剩余寿命预测

本文针对已运行60000h的Waspaloy合金烟气轮机涡轮盘进行剩余寿命预测分析,采用不同试验条件下得到的waspaloy合金持久寿命数据对人工神经网络模型进行训练,得到预测精度较高的模型参数,建立温度、应力等服役条件与持久断裂寿命之间的人工神经网络模型,并利用该模型对Waspaloy合金涡轮盘的剩余寿命进行预测分析。结果表明,中间层节点个数为15时,所建立的人工神经网络模型对Waspaloy合金的持久断裂寿命具有最好的统计预测精度,并可以良好地表征Waspaloy合金剩余持久寿命与服役条件间复杂的非线性关系。     

Effect of interstitial content on high- temperature fatigue crack propagation and low- cycle fatigue of alloy 720

Alloy 720 is a high-strength cast and wrought turbine disc alloy currently in use for temperatures up to about 650 °C in Allison’s T800, T406, GMA 2100, and GMA 3007 engines. In the original composition in-tended for use as turbine blades, large carbide and boride stringers formed and acted as preferred crack initiators. Stringering was attributed to relatively higher boron and carbon levels. These interstitials are known to affect creep and ductility of superalloys, but the effects on low-cycle fatigue and fatigue crack propagation have not been studied. Recent emphasis on the total life approach in the design of turbine discs necessitates better understanding of the interactive fatigue crack propagation and low-cycle fatigue behavior at high temperatures. The objective of this study was to improve the damage tolerance of Alloy 720 by systematically modifying boron and carbon levels in the master melt, without altering the low-cy-cle fatigue and strength characteristics of the original composition. Improvement in strain-controlled low-cycle fatigue life was achieved by fragmenting the continuous stringers via composition modifica-tion. The fatigue crack propagation rate was reduced by a concurrent reduction of both carbon and bo-ron levels to optimally low levels at which the frequency of brittle second phases was minimal. The changes in composition have been incorporated for production disc forgings.     

Effect of cooling rate on the phase transformation and stability of the mushy zone during the solidification of Waspaloy

Scanning electron microscopy(SEM) and energy dispersive X-ray analysis(EDAX) were used to study the microstructure,microsegregation, and fluid flow tendency of the superalloy Waspaloy in the mushy zone,which had been solidified at different cooling rates. The investigation was accompanied with the calculation of Rayleigh numbers.It is found that Ti is the main segregating element and the content of Ti is the highest in the final liquid at the cooling rates of 3-6℃/min.The eta phase(η) precipitate present...     

NEW DEVELOPMENTS IN WROUGHT 718-TYPE SUPERALLOYS

Research and development efforts are still very active on 718-type alloys although two major members of this widely used family, 718 and 625, were invented almost a half-century ago. Emphasis in this type of work at ATI Allvac is directed at improving existing alloys and developing new alloys to meet ever-increasing industrial demands. The improvement of existing alloys is exemplified by addition of minor elements P and B in alloy 718. The discovery of the beneficial effect of P and B in wrought alloy 718 led to development of a new, modified alloy, Allvaca 718 ERa. A large effort has also been directed at studying the effects of major element modifications in 718-type alloys, and a new alloy, Allvaca 718PlusTM, has been developed. The new alloy has much better high temperature capability‘, especially thermal stability‘, approaching the level of Waspaloy but retains excellent processing characteristics, similar to alloy 718. Alloy 718Plus^TM should be useful in any 718-type application requiring a higher working temperature. The properties and processing of this alloy are introduced in this paper.     

Characterization of deformation behavior for waspaloy under creep-fatigue interaction

Hysteresis loops of strain controlled LCF tests for Waspaloy were characterized within the temperature range of 350°C and 600°C. Materials deformation behaviors under symmetric and asymmetric loading conditions were assessed using Chaboche’s viscoplasticity model. The strain hardening and stress relaxation occurring in the loading cycles were estimated. Hardening plays an important role at an early stage of loading, but the stress relaxation becomes dominant at a later stage. The observed change in the slope of hysteresis loops between the first cycle and the second cycle and mean stress relaxation under asymmetric loading conditions may be explained by the evolution of the kinematic hardening variable which depends on the inelastic strain range. The effect of creep on the cyclic shake down is expected to be limited.     

Microstructural development during cold deformation and recrystallisation of 2014 AI–AI2O3 particulate composite

Abstract

The recrystallisation behaviour has been studied in a cold worked 2014 Al–Al₂O₃ particulate reinforced composite which was heat treated to produce two markedly different initial matrix microstructures. The composite was cold deformed to a reduction of either 30 or 50% and then annealed for various times at temperatures in the range 100–500°C. The microstructural development during recrystallisation was studied using optical and transmission electron microscopy (TEM). The recrystallisation kinetics were monitored via hardness measurements and the results correlated with the microstructural analysis. It was observed that the kinetics and temperature of recrystallisation were dependent on the original heat treatment. A detailed TEM investigation indicated that nucleation occurs preferentially at individual and clustered Al₂O₃ particles, but the progress of recrystallisation was controlled by the distribution of dispersoid particles in the matrix. Recrystallisation proceeded rapidly in the composite containing large stable dispersoids. In contrast, when precipitation occurred during annealing, recrystallisation was severely retarded and was controlled by the fine precipitate dispersion.

MST/1566     

Fracture mechanics of surface fatigue crack growth by ductile striation space measurement in notched Waspaloy

Ductile striation space (DSS), a parameter to predict actual cracks in both direction of length and depth, is proposed for the surface fatigue crack behaviors on notched Waspaloy. Three different lengths (1, 2 and 4 mm) of artificial notches are formed as the initial surface crack for an applied maximum stress of 1,103 MPa at the stress ratio R of 0.05. These notches are similar with the appearance of the surface cracks found from the survey of compressor disk. The results show that, all initial crack sites in the depth direction started from the multiple origination sites. The DSS parameter was clearly confirmed, and it also proves the high effectiveness of the measurement in the range of the stress intensity factors for acquiring the crack growth rate on the fractured surface. The surface cracks on Waspaloy at room temperature in an atmosphere perfectly follow the relation of ΔK versus da/dN and db/dN, even though there are, respectively, earlier and later timing differences on the initiation of cracks for the notch sizes of 1 and 4 mm. The results of ΔK versus da/dN and db/dN relations show a similar slope for three different kinds of notches.