Oxygen enhanced crack growth in nickel-based superalloys and materials damage prognosis

This paper summarizes the results from a comprehensive multidisciplinary study to better understand the role of niobium and other strengthening elements in enhancing crack growth by oxygen in nickel-based superalloys at high temperatures, and considers its importance for materials damage prognosis and life cycle engineering in high temperature service. Three γ′ strengthened powder metallurgy (P/M) alloys, with 0, 2.5 and 5 wt pct Nb and comparable volume fractions (about 53 vol pct) of γ′′ precipitates, were specially designed for this study. Coordinated crack growth, microstructural and surface chemistry studies were conducted on the alloys. They were complemented by oxidation studies of Nb, Ni₃Nb, NbC, Ni₃Al and Ni₃Ti, and analyses of fracture surfaces of interrupted crack growth specimens by X-ray photoelectron spectroscopy (XPS). The findings taken in toto show that oxygen enhancement of crack growth is the result of the formation of a brittle film of surface oxides along grain boundaries and interfaces ahead of the crack tip by the preferential oxidation of Nb, Ti and Al in the Nb-rich carbides and Ni₃Al, Ni₃Ti and Ni₃Nb (in Inconel 718) precipitates. The results also showed that the oxidation of Nb-rich carbides alone can significantly enhance crack growth in oxygen. The findings are discussed in relation to the previously proposed crack growth mechanisms, and their applications.     

近平衡与亚快速凝固条件下K424高温合金组织演化规律研究

采用差示扫描量热仪与铜模喷铸技术,研究了较宽冷速(0.17~100 K/s)范围内K424镍基高温合金的近平衡与亚快速凝固行为。利用光学显微镜、扫描电镜及能谱分析仪对不同冷速作用下K424合金γ基体相、γ′沉淀相、MC碳化物及共晶组织进行了表征,并对平均二次枝晶间距进行了定量分析。结果表明：冷速的提高有效细化了初生γ相,二次枝晶间距由0.17 K/s时的84 μm显著下降到100 K/s时的5 μm, 同时导致γ′沉淀相的析出时间缩短,平均晶粒尺寸下降。亚快速凝固条件下所形成的过饱和固溶体在后续加热过程中发生沉淀相析出。枝晶组织的细化与溶质截留的发生,降低了凝固过程中成分偏析,有利于γ+γ′共晶相及碳化物尺寸的下降。     

Influence of service-induced microstructural changes on the aging kinetics of rejuvenated Ni-based superalloy gas turbine blades

Rejuvenation of Ni-based superalloy gas turbine blades is widely and successfully employed in order to restore the material microstructure and properties after service at high temperature and stresses. Application of hot isostatic pressing (HIP) and re-heat treatment can restore even a severely overaged blade microstructure to practically “as-new” condition. However, certain service-induced microstructural changes might affect an alloy’s behavior after the rejuvenated blades are returned to service. It was found that advanced service-induced decomposition of primary MC carbides, and the consequent changes of the γ-matrix chemical composition during the rejuvenation, can cause a considerable acceleration of the aging process in the next service cycle. The paper will discuss the influence of the previous microstructural deterioration on the aging kinetics of rejuvenated gas turbine blades made from IN-738 and conventionally cast GTD-111 alloys.     

铪对FGH97合金平衡相影响的评估

利用材料相图计算和材料性能模拟软件JMatPro,计算了粉末高温合金FGH97热力学平衡相及相组成,研究了不同Hf含量对平衡相和相组成的影响,并结合物理化学相分析实验和显微组织观察进行了验证分析,进而揭示FGH97合金在750℃下各相析出和Hf在相间分配的规律,认清Hf在FGH97合金的作用.结果表明:FGH97合金在750℃下的平衡相包括γ、γ'、MC、M₂₃C₆、M₃B₂和μ相,Hf主要存在于γ'和MC相中,并且随着Hf含量的增大,Hf在γ'和MC相中分配不同.     

高Ru和高Cr对镍基高温合金组织稳定性的影响

在多组元的镍基高温合金中分别和同时加入高Cr和高Ru,经固溶处理后,在800~1100℃下进行10~1300h时效处理,观察组织并分析Ru、Cr以及二者交互作用对合金组织稳定性的影响.结果表明:在无Cr和Ru的合金中,经过1000℃/1300h时效处理后无TCP相析出;加入高Cr的合金仅20h就在晶界发现了TCP相,50h后在枝晶干出现TCP相;在1000℃时效,TCP相比其他温度更易析出.在同时加Cr和Ru的合金中,经过1000℃/1000h时效后并未发现TCP相的析出.这说明高含量的Cr促进了TCP相的形成,而高Ru的添加在高Cr合金中也能有效地抑制TCP相的析出,提高组织稳定性.     

激光增材制造沉淀强化镍基高温合金热裂纹研究进展

针对沉淀强化镍基高温合金中的裂纹现象,对比了2类热裂纹（即凝固裂纹和液化裂纹）的典型特征、形成位置和条件。从枝晶生长、元素偏析、强化相析出、固态相变和残余应力应变等角度,系统综述了热裂纹的形成机理和热裂纹敏感性影响因素。在此基础上,从合金成分调控、工艺参数优化、基板预热以及热等静压处理等方面,概述了增材制造高温合金热裂纹调控和抑制的主要措施。最后,针对激光增材制造沉淀强化镍基高温合金热裂纹研究中存在的问题,提出了进一步研究和发展的建议,为实现无裂纹镍基高温合金的增材制造提供了参考。     

GH36合金中M23C6、VC的界面结构

使用透射电镜观察了GH36合金中M₂₃C₆、VC碳化物和基体之间的界面结构,在M₂₃C₆/γ的半共格界面上分布有错配位错列,间距约10nm。根据${\\rm{\\vec g}}$·${\\rm{\\vec b}}$=0判据,可以确定该位错的Burgers vector ${\\rm{\\vec b}}$=a/2(110)γ,VC/γ的相界面是具有很大点陈错配度(δ=+0.155)的共格界面。最后,从M₂₃C₆、VC和基体之间的不同界面结构与性质讨论了以碳化物沉淀为主要强化手段的Fe基GH36合金的强韧化本质以及如何识别波纹图(Moire pattern)和界面位错的问题。     

Challenge,response and serendipity in the design of materials

A number of condensed case-histories of successful materials innovations are presented to illustrate the author’s thesis that happy accident favouring the prepared mind (i.e. serendipity), or alternatively a response to a challenge from competing materials, are circumstances favouring effective innovation.     

Effects of processing and microstructure on the fatigue behaviour of the nickel-base superalloy René 95

Forms of the nickel-base superalloy René 95 produced by three processing methods were evaluated in tensile, low cycle fatigue and fatigue crack propagation tests at 540 and 650°C. Two powder-metallurgy (PM) forms, hot-isostatically-pressed and extruded-and-forged, and a conventionaslly cast-of-wrought form were all given the same heat treatment. The extruded-and-forged form showed superior fatigue life in low strain range tests though the two PM forms exhibited nearly identical mechanical behaviour in all other respects. Further, this life difference could not be explained by significant differences in the types, sizes or shapes of the defects initiating failure. The cast-and-wroght René 95, however, had lower strenght, ductility and fatigue life, but higher fatigue crack propagation resistance because of a larger grain size. It did not exhibit the environmentally-assisted intergranular mode of propagation which occurs in PM René 95 and other fine-grained superalloys at these test temperatures and frequencies.