Papers by Keyword: CMSX-4

Abstract: This work presents experimental and computational research on the influence of hot isostatic pressing (HIP) of CMSX-4, a second-generation single-crystal nickel-based superalloy, on interdiffusion behavior and the formation of Kirkendall voids in subsequently assembled diffusion couples under isothermal annealing. Two sets of Ni/CMSX-4 diffusion couples were prepared: one using CMSX-4 that had undergone HIP treatment, and the other using CMSX-4 in the as-cast condition. The diffusion couples were annealed at 1250 °C for 144 h. Experimentally measured interdiffusion profiles of all alloying elements, together with synchrotron X-ray 3D μ-tomography of Kirkendall voids, were compared with calculated diffusion profiles and phase-field simulations of void evolution. A direct comparison between the simulation and experimental results enables an explanation of the HIP effect on the density, distribution, and size of the voids, as well as on the observed shifts in the interdiffusion profiles.

Abstract: To pertinently balance growth kinetics, solidification thermodynamics and dendrite expitaxy of multicomponent nickel-based single-crystal supralloy during laser processing, effect of thermometallurgy determinant factors, including laser power, welding speed and welding configuration, on solidification behavior, such as nonequilibrium solidification temperature range, and dendrite growth, such as dendrite trunk spacing, are progressively advanced to forestall solidification cracking phenomena. Symmetric developments of dendrite trunk spacing and solidification temperature range alongside solid/liquid interface are crystallographically driven by useful (001)/[100] welding configuration to auspiciously bring about crack-insusceptible and well-oriented dendrite growth. Dissimilarly, unsymmetrical developments of dendrite trunk spacing and solidification temperature range alongside solid/liquid interface are crystallographically driven by (001)/[110] welding configuration to insidiously favor crack-unresistant and disoriented dendrite growth. Higher heat input thermodynamically and kinetically boosts wide solidification temperature range, appalling stray grain growth with excess of solute ahead of dendrite tip and large size of crack-unresistant region to thermometallurgically disintegrate epitaxial growth for untoward solidification cracking, and therefore should be strictly withstood. Although geometry of symmetrical weld pool both sides is the same in infelicitous (001)/[110] welding configuration, [100] region of dendrite growth is more liable to ruinous stray grain growth and extensive solidification temperature range than [010] region of dendrite growth to complicate dendrite growth and exacerbate weld integrity. The determinant mechanism of crystallography-aided amelioration of solidification cracking resistance as result of kinetics-and thermodynamics-driven dendrite growth is propitiously proposed. Furthermore, the credible and understandable theoretical predictions are in conformity with the experiment results.

Abstract: The effect of thermo-metallurgical factors, such as heat input and welding configuration, on solidification cracking driving forces nearby dendrite tip, such as solidification temperature range and columnar/equiaxed transition (CET) was thermodynamically and kinetically discussed with aid of comprehensive numerical analysis for multicomponent melt-pool solidification during laser processing under non-equilibrium solidification conditions to better understand problematical solidification cracking phenomena. By using (001)/[100] welding configuration, axisymmetrical distributions of columnar/equiaxed transition and solidification temperature range alongside solidification interface are homogeneously produced on both sides of weld pool. By using (001)/[110] welding configuration, nonaxisymmetrical distributions are heterogeneously produced, and are able to bring about infelicitous microstructure degradation. Unidirectional region of [001] columnar dendrite is more prone to epitaxial growth without morphology transition to conservatively better crystallography-assisted single-crystal growth. Unidirectional epitaxial growth is collapsed, and onset of stray grain nucleation and solidification cracking eventuates in [100] region of equiaxed dendrite growth. Low heat input relatively broadens portion of unidirectional columnar dendrite, where stray grain is infrequently nucleated and grown, and thus morphology transition seldom happens, as long as undercooling and solidification temperature range alongside dendrite tip are sufficient low to challengingly develop crackless dendrite growth and high-quality weld by thermometallurgy-aided single-crystallinity control. Auspicious (001)/[100] welding configuration simultaneously abates overall stray grain nucleation and constricts solidification temperature range nearby fusion boundary to wane microstructure heterogeneity. Conversely, plenteous stray grain formation is kinetically attained and extensive solidification temperature range nearby fusion boundary is thermodynamically obtained by problematical (001)/[110] welding configuration to metallurgically induce pernicious equiaxed dendrite and disintegrate dendrite growth. Moreover, the mechanism of solidification cracking diminution as consequence of appropriate optimization of thermo-metallurgical determinants during multicomponent nickel-based single-crystal superalloy melt-pool non-equilibrium solidification is also proposed. The potent consistency between the predicted and experimented results is exceedingly tenable.

Abstract: The heat-treatment processes for the precipitation-strengthened nickel-based superalloys are extremely complicated. The solution heat treatments are designed to dissolve the gamma-prime and the secondary carbide phases and allow the optimum re-precipitation of these phases upon cooling or after aging, for various precipitation-strengthened superalloys. The study was conducted to examine the effects of two solutionizing heat treatments on the microstructure of the CMSX4 superalloy. A comparison between the two obtained microstructures was performed.

Abstract: Variations of a true stress vs. true strain illustrate behaviour of materials during plastic deformation. Stress-strain relationship is generally evaluated by a torsion, compression and tensile tests. Results of these tests provide crucial information pertaining to the stress values which are necessary to run deformation process at specified temperature and cooling rate. Uniaxial compression tests at temperatures below the γ solvus were conducted on nickel based superalloy CMSX-4, to study the effect of temperature and strain rate on its flow stress. On the basis of received flow stress values activation energy of a high-temperature deformation process was estimated. Mathematical dependences (σ_pl -T i σ_pl - ἐ) and compression data were used to determine material constants. These constants allow to derive a formula that describes the relationship between strain rate, deformation temperature and true stress.

Abstract: The occurrence of high temperatures in combustion chambers of jet engines and gas turbines has led to the demand for new technologies and new materials for the manufacture of one of the most critical elements of these systems - the turbine blades. These elements have to withstand extreme temperatures for extended periods without loss of mechanical strength, conditions under which many alloys fail. Such failure is ascribed to the combination of high temperatures and high centrifugal forces, resulting in creep. This is especially prevalent in multi-crystalline structures in which grain boundaries present weaknesses in the structure. High temperature resistant alloys formed as single crystal (SX) structures offer the necessary material properties for safe performance under such extreme conditions. Modelling and simulation techniques were first used to study the directional solidification (DS) of crystal structures during vacuum investment casting. These models allowed the study of the dendritic growth rate, the formation of new grains ahead of the solid/liquid interface and the morphology of the dendritic microstructure. These studies indicated the opportunity to optimise the velocity of the solidification front (solidification rate) for single crystal structures. The aim of this study was therefore to investigate the effect of the solidification rate on the quality of SX castings. The investigations were carried out for nickel-based superalloy CMSX-4 turbine blade casts and rods using the Bridgman process for vacuum investment casting.

Abstract: Characterization of structure defects in turbine blades is the basis for determination of the overall crystalline perfections. This work presents the possibilities of identifying casting defects by combining different X-ray diffraction techniques. The investigation was conducted on samples prepared from as-cast turbine blades airfoil and tips. It was found that X-ray topograms revealed dendritic structure and macro strain areas. The defects areas which have appeared on topograms were also investigated by X-ray diffraction mapping technique by EFG diffractometer. Additionally, the X-ray investigation was complemented by macro SEM images obtained by stitching several images of microstructure. The X-ray maps of misorientation angle and X-ray topograms revealed deviation between the γ’ direction and the blade axis and rotation of the primary dendrite arm around this axis.

Abstract: In the work the single-crystalline alloy CMSX-4 was studied. The main aim of the study was an attempt to find correlations between images of X-Ray topography, X-ray diffraction maps of lattice parameter and misorientation angle and Scanning Electron Microscopy (SEM) images obtained by back-scattered electron (BSE) technique. Topography images were obtained by Auleytner method with wide beam. Diffractometer provided by EFG company was used for obtaining orientation and lattice parameter maps. Material for research was produced in Research and Development Laboratory for Aerospace Materials of Rzeszów University of Technology. Casts were obtained in ALD furnace by the Bridgman technique. It was found that X-ray topograms were correlated with SEM images of microstructures as well as with orientation and lattice parameter maps. X-Ray topograms showed high contrast bands which corresponded to dendrite arms. There was a correlation between low angle boundary and lattice parameter map.

Abstract: In this paper, results concerning the microstructure of Rene N4 alloy layers produced by laser cladding on oriented CMSX-4 single crystal substrates are presented. The microstructure of the deposits was analyzed in the solidification condition after different temperature/time ageing cycles in order to assess the possibility of improving high temperature strength of laser deposited superalloys. The present work demonstrates that single crystalline deposits of René N4 nickel superalloy can be obtained provided that the deposition direction and the processing parameters are properly selected. The clad layer is perfectly bonded to the substrate and presents no pores or cracks. The deposits grow epitaxially on the substrate, so they inherit its orientation. For laser beam powers and scanning speeds varying between 500 to 800 W and 4 to 12 mm/s, respectively and (001) substrates, the deposited material presents a columnar dendritic structure consisting of arrays of similarly oriented dendrites, separated by subgrain boundaries, forming a single crystal. Heat treatments effective for the dissolution of detrimental phases and for inducing the precipitation of cuboid ’-Ni3Al strengthening phase precipitates in the laser clads were established.

Abstract: The lifetime of superalloy single crystals CMSX-4 and CM186LC subjected to tensile mean stress with vibrations at high temperatures has been experimentally studied. Both beneficial and detrimental effect of cyclic stress component has been observed. An increase of lifetime due to superposition of cyclic component on the mean stress is explained by reduction of creep rate due to vibrations. The onset of decrease of lifetime with increasing stress amplitude is observed when the fatigue damage due to initiation and propagation of fatigue crack overbalances the beneficial influence of high frequency cycling.