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

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 Joining Atmosphere in Transient Liquid Phase Bonding of Inconel 617 Superalloy

Metallurgical and Materials Transactions B - In the present paper, transient liquid phase (TLP) bonding of Inconel 617 alloy under the different furnace atmospheres of vacuum, argon gas, and air...     

一种镍基单晶高温合金的瞬态液相连接

研究了一种镍基单晶高温合金的瞬态液相连接方法(TLP)及其对合金组织性能的影响.结果表明,不同温度下Ni-Cr-B熔体对基片均具有良好的润湿性,平衡接触角均小于20°.在等温凝固过程中,随保温时间的增加,固-液界面不断由两侧向中间推移,共晶区宽度不断减小,直至接头中无任何残余液相存在,等温凝固完全结束.共晶区上的硼化物分别为MB和M23B6.TLP连接后的1010℃×248MPa的持久性能达到母材的90%以上.     

Recrystallization of Single Crystal Nickel-Based Superalloy

A series of experiments of investigating the recrystallization of single crystal DD3 superalloy were carried out. The threshold temperature for recrystallization and the effect of annealing temperature on recrystaUization were studied. The results show that the threshold temperature for recrystallization of the shot-peened DD3 samples is be-tween 1 000 ℃ and 1 050℃ under the condition of annealing for 2 h, and the recrystallization depth increases with the rise of the annealing temperature. Below 1 150 ℃, the recrystallization depth increases slowly with the tempera-ture climbing, while above 1 150 ℃, the recrystallization depth increases quickly with the rise of the temperature. The solution of the γ' phase is a critical factor of the recrystallization behavior of DD3 superalloy. In addition, the ki-netics and microstructural evolution of recrystallization at 1 200 ℃ were also studied. It is found that the recrystalli-zation progresses rapidly at 1 200℃ through the growth of fully developed recrystallized grains, and the recrystalli-zation process on the shot-peened surface is similar to that of wrought materials, including nucleation of reerystalliza-tion, growth of new grains into the matrix, and growth of new grains by swallowing up each other.     

On the Time-Temperature-Transformation Behavior of a New Dual-Superlattice Nickel-Based Superalloy

Recent research has identified compositions of nickel-based superalloys with microstructures containing appreciable and comparable volume fractions of γ′ and γ″ precipitates. In this work, an alloy capable of forming such a dual-superlattice microstructure was subjected to a range of thermal exposures between 873 K and 1173 K (600 °C and 900 °C) for durations of 1 to 1000 hours. The microstructures and nature of the precipitating phases were characterized using synchrotron X-ray diffraction and electron microscopy. These data have enabled the construction of a T-T-T diagram for the precipitating phases. Hardness measurements following each thermal exposure have identified the age-hardening behavior of this alloy and allowed preliminary mechanical properties to be assessed.     

An Investigation on High-Temperature Oxidation and Hot Corrosion Resistance Behavior of Coated TLP (Transient Liquid Phase)-Bonded IN738-LC

Despite all achievements to improve nickel-based superalloy, these classes of alloys are still prone to degradation via high-temperature oxidation and hot corrosion. Repairing damaged parts could decrease the life cycle, cost of equipment, and a transient liquid phase (TLP) bonding is a favorable method that has successfully been used for this purpose. One way to increase the lifetime of the repaired parts and the main body is to utilize protective coating. In the current study, aluminized coating was applied on IN738-LC which was first bonded by TLP process. Coating performance on the joint centerline compared to the other parts of the sample was investigated using a scanning electron microscope (SEM and FESEM) and X-ray diffraction method (XRD). The oxidation test result showed that coating provided less protection on the joint centerline due to coating’s chemical composition difference in this area: particularly Fe and Cr. XRD results showed that at the initial time of oxidation, all (α, γ, δ and θ)-Al₂O₃ were formed and by prolonged exposure were transformed to α-Al₂O₃. The hot corrosion test also proved that the joint centerline and the diffusion-affected zone were less resistant to the corrosion attack of 3Na₂SO₄?+?NaCl salts and severity of damage in these zones were clearly distinguished from microscopic images.     

Correlation Between Potentiodynamic Polarization Behaviors of Transient Liquid Phase Bonded 2205 Duplex Stainless Steel and the Bonding Constituents

In order to precisely evaluate the contribution of each bonding constituent to the pitting corrosion resistance of transient liquid phase (TLP) bonded 2205 duplex stainless steel (DSS), we have undertaken potentiodynamic polarization (PDP) and microstructural analytic measurements all across the TLP bonded area. The PDP results show that the pitting corrosion resistance of TLP bonded specimens is significantly affected by the presence of certain bonding constituents across the TLP bonded area. Electron microscopy analysis indicates that the formation of complex (Fe,Ni,Cr,Mo)₃P phosphide in the bonding zone (BZ) before the completion of isothermal solidification (IS) as well as the formation of P-rich sigma phase in the diffusion-affected zone (DAZ) following the completion of the IS provides the most preferential sites for the occurrence of pitting corrosion. The PDP results also confirm that the pitting potentials (E_pit) of the TLP bonded specimen before and after IS completion are, respectively, closer to the E_pit of the BZ and the E_pit of the DAZ rather than to those of other TLP BZs.

     

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

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.     

Interface Development in Cu-Based Structures Transient Liquid Phase (TLP) Bonded with Thin Al Foil Intermediate Layers

Proper bonding and assembly techniques are essential for fabrication of functional metal-based microdevices. Transient liquid phase (TLP) bonding is a promising technique for making enclosed metallic microchannel devices. In this paper, we report results of TLP bonding of Cu-based structures at temperatures between 823 K and 883 K (550 °C and 610 °C) with thin elemental Al foils as intermediate boding layers. In situ X-ray diffraction was utilized to examine the structure of Cu/Al interface in real time, resulting in a proposed sequence of structural evolution of the Cu/Al/Cu TLP bonding interface region. Three different types of bonding interface structures, the “γ ₁ structure,” the “eutectoid structure” (“E structure”), and the “E/γ ₁/E structure,” were observed through electron microscopy, and related to the proposed sequence of interfacial structural evolution. Tensile fracture tests were conducted on TLP-bonded Cu/Al/Cu coupon assemblies. Hardness of the various phases within the bonding interface region was probed with instrumented nanoindentation. Results of mechanical testing were correlated to the structure of the bonding interface region. The present results provide an understanding of the structural evolution within the Cu/Al/Cu TLP bonding interface region, and offer guidance to future bonding of Cu-based microsystems.     

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

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.     

High Temperature Tribological Characterisation of Laser Nitrided Nickel-Based Superalloy

The surface of a nickel-based superalloy used for air-borne gas turbine application was laser nitrided to improve the tribological properties. An optimal laser power and scanning speed was derived to avoid any possible variation in elemental composition of the treated surface. The metallurgical modification over the treated surfaces was studied along the cross-section through microstructural characterisation to understand the refining mechanism and possible nitriding. The coarse grains present over the base material surface reoriented to fine equiaxed grains under lower power and higher interaction time. The grains were refined with higher scanning power and lower interaction time. The higher thermal gradient and cooling rate combination attributed to the refining mechanism. Further increase in the laser power resulted in the formation of columnar grains at the treated depth. The presence of nitride species was observed over the treated surface, which improved the microhardness. All laser treated samples were subjected to wear analysis at ambient and high temperature. The treated pin surface exhibited a combination of adhesive and abrasive wear mechanism. A significant reduction in wear rate was observed for samples treated with high power and lower interaction time.     

Boride Zone Formation in Transient Liquid Phase Bonding of Pairings of Parent Superalloy Materials with Different Compositions and Grain Structures

Two nickel-base superalloys are joined via transient liquid phase (TLP) bonding with boron as the MPD. Boride formation is observed in the parent materials at some distance from the solid/liquid interface. The boron concentration profile over the joint is measured with glow discharge optical emission spectroscopy (GDOES). Boron concentration peaks are observed corresponding to the boride formation. Boron distribution is discussed on the basis of theoretical predictions in the literature. It is concluded that diffusion of another element is necessary to explain the results with the second element influencing the solubility of boron.     

Numerical Simulation of Directional Solidification of a Nickel-Based Superalloy With Applied Direct Current

A macroscopic thermal field calculation and a microstructure simulation are performed to investigate the directional solidification of a nickel-based superalloy with applied direct current in this study.The heat effects of electric current passing through the solidification interface as Joule heat and Peltier heat are investigated in the calculations.The calculated result shows that the Joule heat improves the temperature gradient in the solidification interface,while the effect of Peltier heat is negligible for macroscopic thermal field.The directional growth of dendrites under the influence of Joule heat is investigated with simulation.It is found that under the influence of Joule heat,the dendrites are provided with self-adjustment ability of coordinating growth to achieve flat interface in macroscale during directional solidification with the direct electric current.This interesting phenomenon is brought by the crowdedly passing through the dendrite of electric current in the solidification interface for the large difference of the electrical resistivity between solid state and melt of the superalloy.     

抗热腐蚀高温合金的蠕变组织及其转变

研究了一种新型铸造高温合金K44在高温拉伸蠕变实验中的组织转变.通过光学及电子显微镜观察了合金的铸态组织及高温蠕变过程中不同阶段的组织特征;重点探讨了合金中γ'相的沉淀筏形化、定向粗化及位错与其交互作用.结果表明,多晶高温合金中γ'相的筏形化方向与内应力有关;位错与γ'相的相互作用使加速蠕变阶段较长.蠕变过程中,碳化物形状由骨架状分散为条片状,共晶胞界处γ'相沉淀析出球状γ相;沿着拉伸应力轴方向,从试样根部到断口,滑移系开动数量增多,γ'相的变形越来越大.     

Microstructural Characterization of the White Etching Layer in Nickel-Based Superalloy

Microstructural characterization of the white etching layer (WEL) formed during milling in a fine-grained IN100 Ni-based superalloy was conducted. The microstructure of the layer depended on milling parameters, and under typical machining conditions, where moderate surface speed was used, the white layer exhibited nanostructure character. Fast surface speed produced partial amorphization of the outermost layer. Limited notched low cycle fatigue (LCF) testing was performed, and it was demonstrated that the fatigue properties deteriorated significantly in the specimens where WEL was present in the notch-root surface.     

Nanostructure Particle-Reinforced Transient Liquid Phase Diffusion Bonding: a Comparative Study

Particle-reinforced aluminum–metal matrix composites (Al-MMCs) are used in many engineering applications, because they provide significant advantages when compared to monolithic aluminum alloys. However, there still exists the need to identify a suitable joining process for these materials, which minimizes particulate disruption and retains the strength of the MMC within the joint region. This study presents a comparison between joint qualities achieved when a monolithic interlayer is used vs when a nanoparticle-reinforced composite interlayer is used during transient liquid phase diffusion bonding of Al-6061 alloy containing 15 vol pct of Al₂O₃ particles. Examination of the joint region using scanning electron microscopy (SEM), wavelength dispersive spectroscopy (WDS), and X-ray diffraction (XRD) showed the formation of eutectic phases such as Al₃Ni, Al₉FeNi, and Ni₃Si within the joint zone. The results indicate that the addition of nanoparticle reinforcements into the interlayer can be used to improve joint strength and minimize particle segregation.