Impact strength properties of nickel-based refractory superalloys at normal and elevated temperatures

The dynamic yield and fracture stress of two refractory alloys were measured under shock-wave loading at normal and elevated (up to 680°C) temperatures. The tested materials were polycrystalline nickel-based superalloy Inconel IN738LC and PWA 1483 Ni–Co–Fe alloy in quasi-monocrystalline state. Both alloys are used as turbine blade materials for the hot first stages of gas turbines. The alloys exhibit non-monotonous dependence of the dynamic yield strength upon temperature with an abrupt increase in the temperature interval of 550–600°C. The dynamic tensile strength, in general, is less sensitive to temperature and shows less pronounced increase in the vicinity of 570°C. The observed anomalies of the dynamic strength properties correlate with anomalies in the heat capacity which are associated with the equilibrating of the short-range order in the γ-matrix of the alloys.     

Effect of top and bottom filling on reliability of investment castings in Al,Fe, and Ni based alloys

Abstract

The effect of bottom and top filling running systems on the properties of four investment cast alloys susceptible to contamination by oxide films during filling was studied. The alloys were air cast 2L99 Al–Si–Mg alloy and 254-SMO super duplex stainless steel and vacuum cast IN939 and IN738LC nickel based superalloys. The Weibull moduli for the tensile strength of investment cast bars produced using top and bottom filling were compared as indicators of casting reliability and of oxide damage produced by the running systems. A Weibull modulus of 18 was obtained for top filled 2L99 castings; this was increased to 34 when a correctly designed bottom filling system with a filter was used, thus reflecting the decreased scatter in properties. However, a similar effect was not found for the stainless steel. The use of improved running system designs led to minor increases in the Weibull modulus of the IN738LC and IN939 Ni alloys.     

Schädigungsentwicklung der Legierung IN 738 LC bei Hochtemperatur-LCF-Beanspruchung

Damage evolution of the alloy IN 738 LC at high temperature low cycle fatigue Herrn Professor K.-T. Rie zum 60. Geburtstag Interrupted Low-Cycle-Fatigue tests have been carried out with IN 738 LC at 850°C. The specimens were extensively examined by SEM to quantify the evolution of fatigue damage. Surface crack nucleation at oxidized grain boundaries occured during the whole experiments. The coalescence of cracks was the dominant mechanism which lead to macro crack evolution and the final fracture.     

Effect of aluminium concentration in filler alloys on HAZ cracking in TIG welded cast Inconel 738LC superalloy

Abstract

The effect of concentration of aluminium in filler alloys on heat affected zone (HAZ) microfissuring in TIG welded cast Inconel 738LC (IN 738LC) superalloy was studied. Three fillers, IN 625, IN 617 and Haynes 214, with aluminium concentrations varying from 0·2 to 4·5 wt-%, respectively, were used to TIG weld cast IN 738LC alloy plates subjected to two different preweld heat treatments. One preweld heat treatment was the standard solution heat treatment at 1120°C for 2 h followed by argon quenching. The second was a novel overaging treatment developed by the present authors, termed UM treatment, involving solution treatment at 1120°C followed by air cooling and subsequent ageing at 1025°C followed by water quenching. Detailed microstructural analysis of the welds and base metal was done by optical and analytical electron microscopy. Intergranular microfissures were observed in the HAZ of all the welds, irrespective of the filler alloy and the preweld heat treatment, while no cracks were observed in the fusion zone in any of the samples. The cracks were mostly found to be associated with constitutionally liquated MC carbides, borides, sulphocarbides, γ–γ′ eutectic and γ′ precipitates. The cracking was found to increase with increase in the fusion zone hardness and the aluminium content of the fillers, i.e. it was minimum for IN 625 and maximum for Haynes 214, for a particular preweld heat treatment. Between the two heat treatments, the UM treated samples with a smaller base metal hardness, however, exhibited a considerably reduced HAZ cracking. That is, the hardness of the fusion zone as well as the base metal appears to have a significant effect on the cracking susceptibility of the welds made with different fillers.     

Improvement of grain structure and mechanical properties of a land based gas turbine blade directionally solidified with liquid metal cooling process

Abstract

The manufacturing process of a directionally solidified (DS) IN738LC turbine blade, produced with the liquid metal cooling (LMC) process was improved based on process modelling. The improvement involved varying the system dimensions in the baffle area and optimising the mould thickness, design and the withdrawal parameters. The grain structure of the DS blades produced exhibits a well defined <001>. texture with a few stray grains near the blade top compared to the previous design. Some blades were given to a two stage heat treatment followed by tension tests at 25 and 650°C as well as creep tests at 152 MPa/982°C and 340 MPa/850°C. The yield and tensile strength of improved DS blades were comparable to conventionally cast (CC) IN738LC blades, while the creep properties and the tensile elongation of the DS blades were significantly improved using the optimised LMC process. The LMC system is under more modifications to produce defect free single crystal turbine blades.     

Effect of post heat-treatment on the microstructure and high-temperature oxidation behavior of precipitation hardened IN738LC superalloy fabricated by selective laser melting

The present study investigated the effect of as-built and post heat-treated microstructures of IN738LC alloy fabricated via selective laser melting process on high temperature oxidation behavior.The as-built microstructure showed fine cell and columnar structure due to high cooling rate.Ti element segrega-tion was observed in inter-cell/inter-columnar area.After post heat-treatment,the initially-observed cell structure disappeared,instead bimodal Ni3(Al,Ti)particles formed.High temperature(1273 K and 1373 K)oxidation test results showed parabolic oxidation curves regardless of temperature and initial microstructure.The as-built IN738LC fabricated via the selective laser melting process displayed oxida-tion resistance similar to or slightly better than that of IN738LC fabricated via wrought or cast process.Heat-treated SLM IN738LC,although had similar oxidation weight-gain values to those of the SLM as-built material at 1273 K,showed relatively better oxidation resistance at 1373 K.Bimodal Ni3(Al,Ti)precipitate formed in the post heat treatment changed the local chemical composition,thereby led to changes in alumina former/chromia former location and fraction on the alloy surface.It was concluded that in heat-treated IN738LC increased alumina former fraction was found,and this resulted in excellent oxidation resistance and relatively low weight-gain.     

Microstructure and mechanical properties of nickel based superalloy IN718 produced by rapid prototyping with electron beam melting (EBM)

Abstract

A nickel alloy of a composition similar to that of the nickel based superalloy Inconel alloy 718 (IN718) was produced with the electron beam melting (EBM) process developed by Arcam AB. The microstructures of the as processed and heat treated material are similar to that of conventionally produced IN718, except that the EBM material showed some porosity and the δ phase did not dissolve during the solution heat treatment because the temperature of 1000°C apparently was too low. Mechanical testing of the layer structured material, parallel and perpendicular to the built layers, revealed sufficient strength in both directions. However, it showed only limited elongation when tested perpendicular to the built layers due to local agglomerations of pores. Otherwise, data for the hardness, Young’s modulus, 0·2% yield tensile strength and ultimate tensile strength match those recommended for IN718.     

机械零部件用高强镁合金加工工艺与组织性能研究

针对Mg-Gd-Y合金塑性较差的问题,研究了固溶态和不同温度锻造加工态高强Mg-Gd-Y合金的组织与性能。结果表明,固溶态Mg-Gd合金的晶粒尺寸不均匀,平均尺寸约225μm;当锻造加工温度为440℃和410℃时,合金中第二相的数量较多,大量弥散分布的第二相的存在可以抑制动态再结晶的形成;随着锻造加工温度的降低,Mg-Gd合金的抗拉强度和屈服强度呈现逐渐升高的趋势,在锻造加工温度为470℃时,Mg-Gd合金的断后伸长率达到最大值19.2%,降低锻造加工温度至440℃和410℃时,断后伸长率反而有所降低;固溶态Mg-Gd合金的拉伸断口呈现脆性断裂的特征;锻造加工温度为500℃的拉伸断口呈现混合断裂特征,而锻造加工温度为410℃、440℃和470℃时Mg-Gd合金的断口都呈现为韧性断裂特征。     

Effect of δ Phase on Hydrogen Embrittlement of Inconel 718 by Notch Tensile Tests

The effect of δ phase on the hydrogen embrittlement (HE) sensitivity of Inconel 718 was investigated by conducting notch tensile tests. Notch tensile specimens with various precipitation morphologies of δ phase were prepared with different heat treatments, and hydrogen was charged into the tensile specimens before tensile tests via a cathodic charging process. The loss of notch tensile strength (NTS) due to the charged hydrogen was used to evaluate the hydrogen embrittlement sensitivity. The results show that δ phase has deleterious effect on NTSs, and the fracture of hydrogen-charged specimens initiated near the notch surfaces. The loss of NTS caused by precharged hydrogen can be greatly decreased by dissolving δ phase. δ-free Inconel 718 alloy is proposed for the applications in hydrogen environments.     

Effect of δ Phase on Hydrogen Embrittlement of Inconel 718 by Notch Tensile Tests

The effect of δ phase on the hydrogen embrittlement (HE) sensitivity of Inconel 718 was investigated by conducting notch tensile tests. Notch tensile specimens with various precipitation morphologies of δ phase were prepared with different heat treatments, and hydrogen was charged into the tensile specimens before tensile tests via a cathodic charging process. The loss of notch tensile strength (NTS) due to the charged hydrogen was used to evaluate the hydrogen embrittlement sensitivity. The results show that δ phase has deleterious effect on NTSs, and the fracture of hydrogen-charged specimens initiated near the notch surfaces. The loss of NTS caused by precharged hydrogen can be greatly decreased by dissolving δ phase. δ-free Inconel 718 alloy is proposed for the applications in hydrogen environments.     

Low temperature effects on the fracture behaviour of a nickel base superalloy

The mechanical properties of a solution treated and double aged nickel - 18% iron - 18% chromium alloy (Inconel 718) were studied to assess its utility at temperatures in the ambient-to-cryogenic range. Uniaxial tensile property measurements using unnotched specimens at decreasing temperatures between 295 and 4 K show that yield and ultimate strengths increase by 20% and 29%, respectively, while ductility remains virtually constant. Fracture mechanics tests using 2.54 cm thick compact specimens revealed that the fatigue crack growth resistance of this alloy improves slightly at extreme cryogenic temperatures, and its plane strain fracture toughness, K_lc, increases from 96.3 MPa m^{$\text{1}\text{2}$} at 295 K to 112.3 MPa m^{$\text{1}\text{2}$} at 4 K. These results are compared with similar data for Inconel 750 alloys     

The effect of prior monotonic creep on the resultant fracture toughness and tensile properties of Inconel X-750

Precipitation-hardened polycrystalline nickel-base superalloy type Inconel X-750 was loaded at 700° C and crept to increasing fractions of its creep life. Secondary small fracture-toughness specimens and standard tensile specimens were machined from the initial rather large creep specimens. The secondary specimens were used to study the resultant resistance of the crept alloy to the extension of sharp cracks and its resultant tensile properties as functions of the amount of prior creep. Intergranular formation and coalescence of voids, which took place during the creep process, were responsible for a drastic reduction in the fracture toughness of the alloy long before it reached the end of its creep life. This behaviour indicates that possible deleterious changes in fracture toughness may be the governing factor which determines the useful and safe lives of materials which serve while loaded at high temperatures.     

Al depletion and elemental redistribution in PtAl coated CMSX-4 and IN738LC after high-temperature exposure

Coating application to superalloys provides oxidation and corrosion resistance. One of the key elements in gas turbine coatings is aluminium (Al) which forms a thin, dense alumina layer upon exposure to oxygen and impedes further oxygen diffusion into the alloy. However, Al in the coating depletes due to inward diffusion and oxide formation. The rate of Al depletion is a function of the coating composition/structure, substrate alloy composition/structure and service conditions. In this study, a PtAl diffusion coating, was applied onto polycrystalline IN738LC and single crystal CMSX-4. The coated systems were exposed to 1080°C for 1000 h. Both SEM and XRD analyses were carried out on the as-coated and tested samples. It was found that despite the much higher Al content in CMSX-4, Al depletion was greater. With the higher Cr in IN738LC, a diffusion barrier enriched in Cr/Mo was able to form and reduce the Al depletion.     

Microstructure and mechanical properties of an inertia friction welded INCOLOY alloy 909 – INCONEL alloy 718 joint for rotating applications

Abstract

Inertia welding is a common practice to join axially symmetrical parts for aero-engine applications. The shaft for a new advanced high-pressure compressor will be produced by joining the high strength superalloys INCOLOY® alloy 909 (Incoloy909) and INCONEL® alloy 718 (IN718). IN718 is the work-horse nickel-iron-chromium alloy for a variety of parts for aero-engine applications due to a good combination of relevant mechanical properties, good corrosion resistance and easy fabricability. Incoloy909 is a nickel-iron-cobalt alloy used in aero-engines due to an interesting combination of a nearly constant low coefficient of thermal expansion combined with a constant modulus of elasticity and high strength over a wide range of temperatures. Both alloys are strengthened by precipitationhardening through additions of niobium and titanium. Ring shaped specimens of fully heat-treated Incoloy909 and IN718 are joined by inertia welding. The microstructure in the welded zone is investigated by optical microscopy and transmission electron microscopy with the focus on the Incoloy909 side. Post-weld heat-treatments (PWHT) are evaluated by microstructural investigations and by hardness measurements. The chosen PWHT is characterized by its tensile, creep and load controlled fatigue properties. The results of the mechanical tests are described in terms of the microstructural changes observed in the welded zone.     

High-temperature mechanical properties of Inconel-625: role of carbides and delta phase

Based on the temperature sensitivity characteristics, high-temperature tensile tests were performed at different temperatures and after different solid solution treatments to investigate the effect of Cr-rich M₂₃C₆, Nb-rich MC and the delta phase on the mechanical properties of Inconel 625. The experimental results indicated that the Cr-rich M₂₃C₆ carbides and the Nb-rich MC carbides decomposed at 700°C, which could be the reason for resulting tensile strength anomaly that was observed in a narrow temperature range from 650 to 700°C during the tensile tests at different temperatures. For the samples subjected to a prior solid solution treatment, the size of the δ phase was found to increase with the solution treatment temperature, whereas the elongation at fracture decreased.     

Microstructure and mechanical properties in the TLP joint of FeCoNiTiAl and Inconel 718 alloys using BNi2 filler

High entropy alloy(HEA) of Fe Co Ni Ti Al and Inconel 718 superalloy were firstly transient liquid phase(TLP) bonded by BNi2 filler due to the diffusion of Si and B in the filler to the base metals. The effects of bonding time on microstructure evolution and mechanical properties of the TLP joints were investigated.Owing to the complete isothermal solidification of the joints bonded for 30 min 120 min at 1100°C,no athermally solidified zones(ASZs) formed by eutectic phases were observed in the welded zone. Thus the TLP joints were only composed by the isothermally solidified zone(ISZ) and two diffusion affected zone(DAZ) adjacent to the dissimilar base metals and the negative effect of the ASZ on joint properties can be avoided. In addition, the increase of the bonding time can also make the Ti B2 borides precipitated in the DAZ near HEA and the brittle borides or carbides in the DAZ near IN718 alloy decrease and reduce the possibility of the stress concentration happened in the joints under loading. Therefore, the highest shear strength(632.1 MPa) of the TLP joints was obtained at 1100°C for 120 min, which was higher than that of the joint bonded for 30 min, 404.2 MPa. Furthermore, the extension of the bonding time made the fracture mechanism of the joint be transformed from the intergranular fracture to the transgranular fracture. However, as the brittle borides in the DAZ near IN718 can not be eliminated completely and refining of grains also happened in such region, all the TLP joints fractured inner the DAZ near IN718 alloy.     

Continuous γ′ precipitation in directionally solidified IN738 LC alloy

Abstract

A microstructural characterisation of continuously precipitated γ′ particles in IN738 LC alloy directionally solidified at various cooling rates has been carried out. With decreasing cooling rate there is a trend for the γ′ morphology to vary from rounded particles to irregular cuboids and, finally, a clusterlike formation. In the interdendritic regions, microsegregation leads to an increase in the γ′ solvus temperature, and γ′ precipitation begins at higher temperatures than in the dendrite cores, resulting in differences in particle size and morphology. Observations on the effects of solution treatment and aging on the development of γ′ dispersions are also reported.     

Superplastic behaviour of Inconel 718 sheet

Abstract

Inconel 718 is a nickel based alloy used extensively in the aerospace industry, having good service capabilities, in terms of strength and fatigue resistance, at high temperatures. Inconel 718, in the form of sheet, has the capability of being shaped using gas pressure forming techniques similar to those used for a number of aluminium and titanium based alloys. An extensive research programme has been carried out to investigate the high temperature formability of this alloy. This has involved both uniaxial tensile testing to determine such parameters as flow stress and strain rate sensitivity, and microstructural examination to investigate grain stability under both static heating and following deformation. The forming characteristics of the material have been correlated with the δ phase solvus temperature determined using SEM techniques. Optimum forming temperatures and strain rates are discussed.     

Joint strength and interfacial microstructure in silicon nitride/nickel-based Inconel 718 alloy bonding

Joining of Inconel 718 alloys to silicon nitrides using Ag–27Cu–3Ti alloys was performed to investigate the microstructural features of interfacial phases and their effect on joint strength. The Si3N4/Inconel 718 alloy joints had a low shear strength in the range 70.4–46.1 MPa on average, depending on joining temperature and time. When the joining time was held for 1.26 ks at 1063 K, shear, tension, and four-point bending strength were 70.4, 129.7, and 326.5 MPa on average. The microstructures of the joints typically consisted of six types of phases. They were TiN and Ti5Si4 between silicon nitride and filler metal, a copper- and silver-rich phase, island-shaped Ti–Cu phase, a Ti–Cu–Ni alloy layer between filler and base metal, and diffusion of titanium into the Inconel 718 alloys. With increasing joining temperature, the thickness increase of the Ti–Cu–Ni alloy layer was much greater than that of the reaction layer. Thus the diffusion rate of titanium into the base metal was much greater than the reaction rate with silicon nitride. This behaviour of titanium results in the formation of a Ti–Cu–Ni alloy layer in all the joints. The formation of these layers was the cause of the strength degradation of the Si3N4/Inconel 718 alloy joints. This fact was supported by the analyses of fracture path after four-point bending strength tests.     

Effect of different heat treatments on the microstructure and mechanical properties in selective laser melted INCONEL 718 alloy

The microstructure and tensile properties of selective laser melted (SLM) Inconel 718 alloy were studied in the as-printed and different heat treat conditions. The SLM as-print microstructures exhibited columnar grain structures with very fine dendritic structure with segregation of elements. Apart from the standard heat treatment, three other heat treat cycle variants were carried out in an attempt to remove the extensive segregation of elements and modify the textured grain structure of the SLM as-print microstructure. Increasing the homogenization temperature reduced the segregation and coarsened the grain structure. However, the grains still remained columnar, and the material became softer with reduction in strength. After the ageing treatment, the tensile strength improved significantly for all the heat treated samples, which is typical for precipitation hardening of IN718 alloy. The microstructures of the heat treated samples exhibited the needle shaped δ, carbides, and finely dispersed γ″, γ′ phases.