偏离度对抗热腐蚀单晶高温合金DD483拉伸性能的影响

用螺旋选晶器法制备DD483抗热腐蚀单晶高温合金,在偏离度小于100时测试合金从室温到1 000℃的瞬时拉伸性能:研究0～30.范围内偏离度对合金室温和950℃拉伸性能的影响.结果表明:由于单相γ'的反常屈服行为,750 ℃时合金的抗拉强度达到峰值1 300 MPa,屈服强度达到1 105 MPa;偏离度在0～30°范围内,DD483合金室温及950℃时的屈服强度和抗拉强度均随偏离度增加而减小,塑性随偏离度的增加而增大;不同偏离度样品的室温拉伸的变形机制并没有明显差别,拉伸性能的差异主要在于Schmid因子和弹性模量的不同;950℃时由于开动滑移系数目的增加,偏离度对合金拉伸强度的影响相对室温的影响减小.     

镍基单晶高温合金涡轮叶片薄壁效应研究进展

镍基单晶高温合金具有优异的高温综合性能,是航空发动机涡轮叶片和导向叶片等部件的首选材料,承受高温度和高应力的严苛服役环境。目前,高冷效叶片的结构设计中采用多种复杂冷却结构以提高其承温能力,其中以层板冷却和双层壁冷却为代表的微型冷却结构是其主流发展方向。但由于这类复杂涡轮叶片中存在超薄壁结构,已成为叶片制造的关键点和难点。本文综述了镍基单晶高温合金薄壁结构的发展趋势,分析了薄壁受限空间的缺陷产生及枝晶生长规律,阐述了薄壁结构对力学性能的影响,展望了先进涡轮叶片的制备及其组织控制的发展趋势。     

Preparation and characterization of LPPS NiCoCrAlYTa coatings for gas turbine engine

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Multiscale modelling and simulation of single crystal superalloy turbine blade casting during directional solidification process

As the key parts of an aero-engine,single crystal（SX）superalloy turbine blades have been the focus of much attention.However,casting defects often occur during the manufacturing process of the SX turbine blades.Modeling and simulation technology can help to optimize the manufacturing process of SX blades.Multiscale coupled models were proposed and used to simulate the physical phenomena occurring during the directional solidification（DS）process.Coupled with heat transfer（macroscale）and grain growth（meso-scale）,3D dendritic grain growth was calculated to show the competitive grain growth at micro-scale.SX grain selection behavior was studied by the simulation and experiments.The results show that the geometrical structure and technical parameters had strong influences on the grain selection effectiveness.Based on the coupled models,heat transfer,grain growth and microstructure evolution of a complex hollow SX blade were simulated.Both the simulated and experimental results show that the stray grain occurred at the platform of the SX blade when a constant withdrawal rate was used in manufacturing process.In order to avoid the formation of the stray crystal,the multi-scale coupled models and the withdrawal rate optimized technique were applied to the same SX turbine blade.The modeling results indicated that the optimized variable withdrawal rate can achieve SX blade castings with no stray grains,which was also proved by the experiments.     

The corrosion behavior of TiN coated and uncoated incoloy 800 alloy

Incoloy alloy 800 is used in a variety of applications in industry as well as in domestic appliances for sheeting on electric heating elements. The composition of the alloy enables it to resist deterioration in many corrosive environments. However, resistance of the alloy to corrosion in aqueous media needs to be further examined. The present study examines the corrosion properties of Incoloy 800 alloy of both coated and uncoated workpieces obtained in a 0.1N H₂SO₄ + 0.05N NaCl solution. TiN coating is achieved using a physical vapor deposition (PVD) technique while corrosion tests are carried out using electrochemical polarization methods. Moreover, in order to examine the influence of hydrogen diffusion, reduction of hydrogen at the Incoloy 800 surface is carried out in a solution of 0.1N HNO₃ + 1 g/L thiourea. Tensile tests are conducted on the workpieces to determine the influence of hydrogen embrittlement on the resulting mechanical properties of the substrate. To examine the pit formation and stress induced microcracking, scanning electron microscope (SEM) analysis is carried out. The results show that the corrosion resistance of the alloy improves after TiN coating. In addition, no specific pattern or differentiation on the pit geometry is observed. The pitting rate and its size reduce considerably for TiN coated workpieces.     

Oxidation and alkali sulfate‐induced corrosion of aluminide diffusion coating with and without platinum

A platinum‐free (MDC210) and a platinum‐rich (MDC150L) aluminide diffusion coating applied to a CMSX4 single crystal Ni‐based superalloy were investigated after exposure to sulfate‐induced corrosion and oxidation at 900 °C for a total of 100 h. Weight changes, microstructural, and microchemical analyses of the products were performed by the means of gravimetry, scanning electron microscopy (SEM), energy dispersive X‐ray (EDX), and X‐ray diffraction (XRD). Platinum was found to have a beneficial effect on both the oxidation and corrosion resistance of the coating. In both cases the scale was thicker on the platinum‐free coating. However, the difference in the extent of oxidation of the two coatings was small.     

单晶高温合金的选晶行为

对高温合金单晶选晶生长工艺进行了实验研究,揭示了螺旋选晶器和缩颈选晶器的原理,实验结果表明,在螺旋选晶器中,晶体横向拚优生长与螺旋结构的耦合作用,形成连续选晶过程,是螺旋选晶的主要原理,其选晶作用良好;而在缩颈选晶器中,几乎只存在单一的机械阻隔选晶行为,多重缩颈结构对于改善选晶作用并不明显,选晶效果不好。     

晶体取向及析出相对Al-Cu-Li单晶腐蚀行为的影响（英文）

通过扫描电子显微镜、透射电子显微镜、光学显微镜、剥落腐蚀溶液浸泡实验和电化学测试研究晶体取向和析出相对Al-Cu-Li单晶腐蚀行为的影响。结果表明,时效态Al-Cu-Li合金不同取向的腐蚀速率按(001)<(101)<(111)的顺序增加,与淬火态合金的腐蚀速率按(111)<(001)<(101)的顺序增加明显不同。T₁相的析出恶化了Al-Cu-Li合金的耐蚀性,且不同晶面取向的恶化程度不同。时效态合金的严重局部腐蚀沿着晶体学方向扩展,并以腐蚀带的形式沿{111}_Al面扩展。     

Hot Corrosion of a Single Crystal Ni-Base Superalloy by Na-Salts at 900°C

The hot corrosion behaviors of a single crystal (SC) Ni-base superalloy coated with Na₂SO₄ and 75 wt.% Na₂SO₄-25 wt.% NaCl mixture were studied in air at 900°C. The results showed that the corrosion productions were laminar structure, porous and easily spalled. And sulfides formed quickly in the deep SC superalloy under the corrosion production. The addition of NaCl into Na₂SO₄ considerably accelerated the corrosion of the SC superalloy, and the corrosion scale became more porous. The hot corrosion process was explained based on sulfide formation and its subsequent oxidation.     

Hot corrosion of TBC-coated components upon combustion of low-sulfur fuels

Gas turbine reliability is a crucial requirement for passenger safety in aviation and a secure energy supply. Hence, corrosive degradation of combustor parts, vanes, and blades in gas turbines must be prevented. One of the most severe forms of corrosion is alkali-sulfate-induced hot corrosion, which is associated with internal sulfidation of components and is usually anticipated to fade in importance in the absence of sulfur. However, the literature suggests that hot corrosion might still occur in low-sulfur combustion gases. In this study, established thermodynamic modeling methods are used to analyze the low-sulfur hot corrosion regime. Liquid sodium chromate is found to be stable in these conditions. A comparison of calculation results and engine findings suggests that high alkali levels can negatively impact thermal barrier coating life even if sulfur is absent in the fuel. Laboratory tests are carried out to validate the chromate formation on MCrAlY-coated specimens. It is shown that molten sodium chromate can alter the oxidation behavior of MCrAlY, promoting the formation of voluminous spinel. This represents a new and different form of hot corrosion compared to type I hot corrosion.     

螺旋选晶器对单晶高温合金晶粒取向的影响(英文)

对于航天推进和发电燃气轮机,为了实现更高的效率和性能并同时降低成本和排放,需要发展先进的镍基单晶高温合金。随着合金的发展,合金的铸造技术已经从定向凝固(DS)发展到单晶(SX)。单晶取向与择优取向的偏差已经成为单晶高温合金最重要的铸造缺陷之一。在自行设计的高温度梯度定向凝固装置中,采用改进的Bridgeman法,用螺旋选晶器拉制出DZ417G合金的单晶。使用XRD和EBSD对其取向进行分析研究。结果表明:较小角度的螺旋选晶器可以有效地减少单晶取向与择优取向的偏差。     

渗铝镍基高温合金热腐蚀行为研究

采用低压气相渗铝工艺制备铝化物涂层 ,在涂层表面涂敷不同NaCl+Na2 SO4 含量的熔盐进行 90 0℃热腐蚀实验 .结果表明 ,涂层对NaCl含量不敏感 ,这与涂层表面生成Al2 O3 氧化膜有关 .涂层能有效提高合金抗热腐蚀性能 .     

Structure defect prediction of single crystal turbine blade by dendrite envelope tracking model

The structure defects such as stray grains during unidirectional solidification can severely reduce the performance of single crystal turbine blades. A dendrite envelope tracking model is developed for predicting the structure defects of unidirectional solidification turbine blade. The normal vector of dendrite envelope is estimated by the gradient of dendrite volume fraction, and the growth velocity of the dendrite envelope （dendrite tips） is calculated with considering the anisotropy of grain growth. The solute redistribution at dendrite envelope is calculated by introducing an effective solute partition coefficient. Simulation tests show that the solute-build-up due to the rejection at envelope greatly affects grain competition and consequently solidification structure. The model is applied to predict the structure defects （e.g. stray grain） of single crystal turbine blade during unidirectional solidification. The results show that the developed model is reliable and has the following abilities： reproduce the growth competition among the different-preferential-direction grains; predict the stray grain formation; simulate the structure evolution （single crystal or dendrite grains）.     

Surface recrystallization of single crystal nickel-based superalloy

As-cast single crystal (SC) superalloy samples were shot peened and then annealed at different temperatures to investigate the effect of annealing temperature on the surface recrystallization behavior of the SC superalloy. The results show that the depth of recrystallized layers increases with the increase of annealing temperature. Below 1200 °C, the recrystallization depth climbs slowly with temperature rising. Above 1200 °C, the recrystallization depth increases sharply with the rise of temperature. The morphology of recrystallized grains is significantly affected by annealing temperature. Below the γ′ solvus, cellular recrystallization may be observed. Above the γ′ solvus, recrystallization occurs through the growth of well developed recrystallized grains. In addition, the microstructure evolution of recrystallized grains at the homogenization annealing temperature was studied. It is found that recrystallized grains first nucleate in the dendritic core areas on the shot-peened surface and then grow inwards along the dendritic core areas. With the dissolution of the coarse γ′ precipitates and γ′/γ′ eutectics in the interdendritic areas, the recrystallized grain boundaries move through the interdendritic areas. Finally, the fully developed grains nearly have a uniform depth. The dissolution of primary γ′ precipitates is a critical factor influencing the recrystallization behavior of SC superalloys.     

单晶DD3与细晶FGH4095高温合金摩擦焊接头组织

对单晶DD3与粉末细晶FGH4095高温合金摩擦焊接接头,采用光学显微镜及SEM-EDS分析了接头组织、焊合区成分变化及接头连接机理.结果表明,焊合区两侧材料均形成了动态再结晶晶粒;连接界面位于两侧动态再结晶晶粒之间;连接界面两侧合金元素发生了扩散;两侧动态再结晶晶粒均有向对方弓形凸入长大的趋势,通过形成共同晶粒,实现两种异质材料的连接;FGH4095侧的动态再结晶晶粒向DD3一侧长大的趋势较大.DD3与FGH4095摩擦焊接过程中发生了摩擦面转移,实际的摩擦变形主要在DD3摩擦带内部,接头组织变化梯度大.     

Effect of cobalt on chemical segregation and solution process in Re-containing single crystal superalloys

The effect of cobalt on chemical segregation and solution process in three nickel base single crystal superalloys was investigated. Three alloys containing the mass fi＇action of cobalt of 12% （named Alloy 1 ）, 3% （named Alloy 2） and 0 （named Alloy 3）, respectively were studied, in which the contents of other elements were same. The results show that the segregation extent of W, Re, Ta, Al between dendrite and interdendritic region rises with the increase of cobalt content. The incipient melting points decrease by 10 ℃ and 20 ℃ respectively when the content of cobalt increases from 0 through 3% to 12%. During solid solution at 1 340 ℃, the solid solution of large gamma prime in interdendritic region and the dissolution of eutectic in alloy 1 become easier than in other two alloys. After heat-treatment at 1 340℃ for 8 h, the segregation extent of elements in alloy 1 decreases dramatically, while in alloy 2 and alloy 3, the segregation ratios decrease slowly. It suggests that the higher content of cobalt can accelerate the diffusion process at high temperature.     

溅射Ni-16Co-26Cr-10Al纳米晶涂层的熔盐热腐蚀性能

利用磁控溅射技术在铸造Ni-16Co-26Cr-10Al合金上溅射了相同成分的纳米晶涂层,并进行900℃热腐蚀实验,结果表明:溅射Ni-16Co-26Cr-10Al纳米晶涂层由于晶粒尺寸细小,促进了保护性氧化物形成元素Al沿原"短路扩散通道-晶界"向氧化前沿的扩散,从而促进了保护性Al2O3的快速形成,使得溅射Ni-16Co-26Cr-10Al纳米晶涂层表现出比M38合金更优异的抗热腐蚀性能。     

燃气轮机在海洋环境下的热腐蚀与防护技术研究进展

针对海洋环境下舰船燃气轮机的热腐蚀现状,从热腐蚀的机理研究着手,基于不同阶段提出的热腐蚀模型理论,分析了高温和低温两种热腐蚀类型的发生过程和表现特征,指出热腐蚀实质上是以Na2SO4为主导的熔盐沉积共晶物与金属基体发生反应而导致金属材料加速氧化的过程。在此基础上,详细介绍了三种涂层防护技术—扩散涂层、覆盖涂层和热障涂层,并根据这三种涂层的发展阶段和功能特性,分析了其在制备工艺、作用机理和应用领域上表现出的差异性,重点强调了热障涂层(TBCs)在当前的发展境况。结合世界各国研究者开展的代表性工作,全面综述了国内外在舰船燃机热腐蚀防护领域的研究进展,重点描述了以硫酸盐为主的腐蚀介质中,金属材料的热腐蚀表现特征,并展示了数值模拟、热力学模拟等方法在热腐蚀研究上的应用案例。最后,对舰船燃气轮机涂层防护技术的发展方向进行了展望,提出发展新一代环障涂层(EBCs)是提高燃气轮机综合防护能力的有效技术手段。