The kinetics, morphology and composition of the formation of TCP phases in an experimental alloy containing no tungsten is studied. At high temperature P phase forms after 20 h, whereas below 950°C the phases p and R occur. At lower temperatures a polycrystalline form of cr phase is observed which is meta-stable but acts as a nucleation site for the other phases. The phase occurrence and compositions are compared with a thermodynamic model using a rhenium-containing database, and reasonable agreement is found for the P, R and cs phases. However the model underestimates the stability of the p phase.
Turbine inlet temperatures over the next few years will approach 1650°C (3000°F) at maximum power for the latest large commercial turbofan engines, resulting in high fuel efficiency and thrust levels approaching 445 KN (100,000 lbs.). High reliability and durability must be intrinsically designed into these turbine engines to meet operating economic targets and ETOPS certification requirements. This level of performance has been brought about by a combination of advances in air cooling for turbine blades and vanes, design technology for stresses and airflow, single crystal and directionally solidified casting process improvements, and the development and use of rhenium (Re) containing high γ′ volume fraction nickel-base superalloys with advanced coatings, including full-airfoil ceramic thermal barrier coatings. Re additions to cast airfoil superalloys not only improves creep and thermo-mechanical fatigue strength, but also environmental properties including coating performance. Re dramatically slows down diffusion in these alloys at high operating temperatures. A team approach has been used to develop a family of two nickel-base single crystal alloys (CMSX-4® containing 3 percent Re and CMSX®-10 containing 6 percent Re) and a directionally solidified, columnar grain nickel-base alloy (CM 186 LC® containing 3 percent Re) for a variety of turbine engine applications. A range of critical properties of these alloys is reviewed in relation to turbine component engineering performance through engine certification testing and service experience. Industrial turbines are now commencing to use this aero developed turbine technology in both small and large frame units in addition to aero-derivative industrial engines. These applications are demanding, with high reliability required for turbine airfoils out to 25,000 hours, with perhaps greater than 50 percent of the time spent at maximum power. Combined cycle efficiencies of large frame industrial engines are scheduled to reach 60 percent in the U. S. ATS programme. Application experience to a total 1.3 million engine hours and 28,000 hours individual blade set service for CMSX-4 first stage turbine blades is reviewed for a small frame industrial engine.
A team approach involving a turbine engine company (Rolls-Royce), its single-crystal casting facilities, and a superalloy developer and ingot manufacturer (Cannon-Muskegon), utilizing the concepts of simultaneous engineering, has been used to develop CMSX-4 alloy successfully for turbine blade applications. CMSX-4 alloy is a second-generation nickel-base single-crystal superalloy containing 3 percent (wt) rhenium (Re) and 70 percent volume fraction of the coherent γ′ precipitate strengthening phase. Its finely balanced composition offers an attractive range of properties for turbine airfoil applications. In particular the alloy’s combination of high strength in relation to creep-rupture, mechanical and thermal fatigue, good phase stability following extensive high temperature, stressed exposure and oxidation, hot corrosion and coating performance, are attractive for turbine engine applications where engine performance and turbine airfoil durability are of prime importance. The paper details the single-crystal casting process and heat treatment manufacturing development for turbine blades in CMSX-4 alloy. Competitive single-crystal casting yields are being achieved in production and extensive vacuum heat treatment experience confirms CMSX-4 alloy to have a practical production solution heat treat/homogenization “window.” The creep-rupture data-base on CMSX-4 alloy now includes 325 data points from 17 heats including 3630 kg (8000 lb) production size heats. An appreciable portion of this data was machined-from-blade (MFB) properties, which indicate turbine blade component capabilities based on single-crystal casting process, component configuration, and heat treatment. The use of hot isostatic pressing (HIP) has been shown to eliminate single-crystal casting micropores, which along with the essential absence of γ/γ′ eutectic phase, carbides, stable oxide, nitride and sulfide inclusions, results in remarkably high mechanical fatigue properties, with smooth and particularly notched specimens. The Re addition has been shown not only to benefit creep and mechanical fatigue strength (with and without HIP), but also bare oxidation, hot corrosion (sulfidation), and coating performance. The high level of balanced properties determined by extensive laboratory evaluation has been confirmed during engine testing of the Rolls-Royce Pegasus turbofan.
Twenty-two Ni-base superalloy compositions were investigated to assess the influence of the constituent elements on their solidification characteristics. Increasing the amount of Cr and Mo in high refractory single crystal alloys appears to reduce the extent of microsegregation of the dense refractory elements, W and Re. This is likely to be advantageous for maintaining single crystal solidification since alloys containing elevated levels of W and Re are prone to the formation of macroscopic grain defects during single crystal solidification. These findings suggest that elemental interactions between Cr, Mo, W and Re need to be considered when optimising alloys for high temperature creep properties. Ru additions also appear beneficial not only through stabilisation of the microstructure with respect to topological-close-packed (TCP) phase formation but also by reducing the degree to which Re partitions to the dendrite core. Linear regression has been applied to predict the solid-liquid partition coefficients for the major constituent elements and therefore provide an indication of the susceptibility of a given composition to freckle formation during directional solidification.
Fourth-generation, Ru-bearing, Ni-base superalloys offer superior microstructural stability over previous generations, affording greater density-corrected creep strength, but in common with their predecessors, have only borderline ability to form and maintain a protective oxide layer. This is particularly so at intermediate temperatures of around 750°C at which temperature internal oxidation can occur. In this present study, the nature of this attack has been examined in experimental 3 and 5 mass % Ru alloys. Both these alloys exhibited dispersed regions of oxide-filled pits whose depth increased parabolically with isothermal exposure time at a similar rate. Pits appear to nucleate progressively straight from the initial competitive oxidation stage. In all cases, the pits were associated with a surface mound of nickel-and cobalt-rich oxides. The results of detailed metallographic examination of the internal oxidation products are provided.
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