The effect of gamma-gamma ` interface on the tensile and shear strengths of nickel-based superalloys: A first-principles study

First-principles density functional theory has been used to evaluate the shear and cleavage strength in terms of Griffith work and generalized stacking fault energy (GSF) of (001) plane for gamma, gamma' and gamma-gamma' system as a function of distance from the gamma/gamma' interface. Calculation of Griffith work suggests higher cleavage energy for bulk gamma as compared to gamma' while the GSF calculation suggests higher shear strength for bulk gamma' as compared to gamma. It has been found that the shear strength of the cubic plane of the gamma/gamma' interface is marginally lower than those of bulk gamma and gamma' phases. (C) 2014 Elsevier B.V. All rights reserved.

Multi-scale modelling of Suzuki segregation in gamma' precipitates in Ni and Co-base superalloys

The high temperature strength of alloys with (gamma +gamma') microstructure is primarily due to the resistance of the ordered precipitate to cutting by matrix dislocations. Such shearing requires higher stresses since it involves the creation of a planar fault. Planar fault energy is known to be dependent on composition. This implies that the composition on the fault may be different from that in the bulk for energetic reasons. Such segregation (or desegregation) of specific alloying elements to the fault may result in Suzuki strengthening which has not been explored extensively in these systems. In this work, segregation (or desegregation) of alloying elements to planar faults was studied computationally in Ni-3(Al, Ti) and Co-3(W, Al) type gamma' precipitates. The composition dependence of APB energy and heat of mixing were evaluated from first principle electronic structure calculations. A phase field model incorporating the first principles results, was used to simulate the motion of an extended superdislocation under stress concurrently with composition evolution. Results reveal that in both systems, significant (de) segregation occurs on equilibration. On application of stress, solutes were dragged along with the APB in some cases. Additionally, it was also noted the velocity of the superdislocation under an applied stress is strongly dependent on atomic mobility (i. e. diffusivity).

Computational design of model Re/Ru bearing Ni-base superalloys

It is well established that Re and Ru additions to Ni-base superalloys result in improved creep performance and phase stability. However, the role of Re and Ru and their synergetic effects are not well understood, and the first step in understanding these effects is to design alloys with controlled microstructural parameters. A computational approach was undertaken in the present work for designing model alloys with varying levels of Re and Ru. Thermodynamic and first principles calculations were employed complimentarily to design a set of alloys with varying Re and Ru levels, but which were constrained by constant microstructural parameters, i.e., phase fractions and lattice misfit across the alloys. Three ternary/quaternary alloys of type Ni-Al-xRe-yRu were thus designed. These compositions were subsequently cast, homogenized and aged. Experimental results suggest that while the measured volume fraction matches the predicted value in the Ru containing alloy, volume fraction is significantly higher than the designed value in the Re containing alloys. This is possibly due to errors in the thermodynamic database used to predict phase fraction and composition. These errors are also reflected in the mismatch between predicted and measured values of misfit.

Growth mechanism of the interdiffusion zone between platinum modified bond coats and single crystal superalloys

Pt-modified beta-NiAl bond coats are applied over the superalloys for oxidation protection in jet engine applications. However, as shown in this study, it also enhances the growth of the interdiffusion zone developed between the bond coat and the superalloy along with brittle precipitates. Location of the Kirkendall plane indicates that a precipitate free sublayer grows from the bond coat, whereas another sublayer grows from the superalloy containing very high volume fraction of precipitates. With increasing Pt content, thickness of both the sublayers increases because of an increase in diffusion rates of the components. Quantitative electron probe microanalysis indicates high concentration of refractory components in the precipitates. Transmission electron microscopy shows that Rene N5 superalloy produces TCP phases mu and P, whereas CMSX-4 superalloy produces mu and sigma in the interdiffusion zone. With increasing Pt content in the bond coat, the average size of the precipitates decreases when coupled with Rene N5. Precipitates become much finer when the same bond coats are coupled with CMSX-4. (C) 2015 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Growth mechanism of the interdiffusion zone between platinum modified bond coats and single crystal superalloys

Pt-modified beta-NiAl bond coats are applied over the superalloys for oxidation protection in jet engine applications. However, as shown in this study, it also enhances the growth of the interdiffusion zone developed between the bond coat and the superalloy along with brittle precipitates. Location of the Kirkendall plane indicates that a precipitate free sublayer grows from the bond coat, whereas another sublayer grows from the superalloy containing very high volume fraction of precipitates. With increasing Pt content, thickness of both the sublayers increases because of an increase in diffusion rates of the components. Quantitative electron probe microanalysis indicates high concentration of refractory components in the precipitates. Transmission electron microscopy shows that Rene N5 superalloy produces TCP phases mu and P, whereas CMSX-4 superalloy produces mu and sigma in the interdiffusion zone. With increasing Pt content in the bond coat, the average size of the precipitates decreases when coupled with Rene N5. Precipitates become much finer when the same bond coats are coupled with CMSX-4. (C) 2015 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

An example of the use of neural computing techniques in materials science - The modelling of fatigue thresholds in Ni-base superalloys

Two adaptive numerical modelling techniques have been applied to prediction of fatigue thresholds in Ni-base superalloys. A Bayesian neural network and a neurofuzzy network have been compared, both of which have the ability to automatically adjust the network's complexity to the current dataset. In both cases, despite inevitable data restrictions, threshold values have been modelled with some degree of success. However, it is argued in this paper that the neurofuzzy modelling approach offers real benefits over the use of a classical neural network as the mathematical complexity of the relationships can be restricted to allow for the paucity of data, and the linguistic fuzzy rules produced allow assessment of the model without extensive interrogation and examination using a hypothetical dataset. The additive neurofuzzy network structure means that redundant inputs can be excluded from the model and simple sub-networks produced which represent global output trends. Both of these aspects are important for final verification and validation of the information extracted from the numerical data. In some situations neurofuzzy networks may require less data to produce a stable solution, and may be easier to verify in the light of existing physical understanding because of the production of transparent linguistic rules. © 1999 Elsevier Science S.A.

Homogenization of Precipitation Hardening Nickel Based Superalloys

Allvac 718 Plus and Haynes 282 are relatively new precipitation hardening nickel based superalloys with good high temperature mechanical properties. In addition, the weldability of these superalloys enhances easy fabrication. The combination of high temperature capabilities and superior weldability is unmatched by other precipitation hardening superalloys and linked to the amount of the γ’ hardening precipitates in the materials. Hence, it is these properties that make Allvac 718 Plus and Haynes 282 desirable in the manufacture of hot sections of aero engine components. Studies show that cast products are less weldable than wrought products. Segregation of elements in the cast results in inhomogeneous composition which consequently diminishes weldability. Segregation during solidification of the cast products results in dendritic microstructure with the segregating elements occupying interdendritic regions. These segregating elements are trapped in secondary phases present alongside γ matrix. Studies show that in Allvac 718Plus, the segregating phase is Laves while in Haynes 282 the segregating phase is not yet fully determined. Thus, the present study investigated the effects of homogenization heat treatments in eliminating segregation in cast Allvac 718 Plus and Haynes 282. Paramount to the study was the effect of different homogenization temperatures and dwell time in the removal of the segregating phases. Experimental methods used to both qualify and quantify the segregating phases included SEM, EDX analysis, manual point count and macro Vickers hardness tests. Main results show that there is a reduction in the segregating phases in both materials as homogenization proceeds hence a disappearance of the dendritic structure. In Allvac 718 Plus, plate like structures is observed to be closely associated with the Laves phase at low temperatures and dwell times. In addition, Nb is found to be segregating in the interdendritic areas. The expected trend of increase in Laves as a result of the dissolution of the plate like structures at the initial stage of homogenization is only detectable for few cases. In Haynes 282, white and grey phases are clearly distinguished and Mo is observed to be segregating in interdendritic areas.

Corrosion of superalloys by selected fused salts

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Modification of the B2-type matrix of aluminide diffusion coatings on nickel-base superalloys-bulk aluminide analogues

Pack aluminide coating is a useful method for conferring oxidation resistance on nickel-base superalloys. Nominally, these coatings have a matrix composed of a Ni-Al based B2-type phase (commonly denoted as Β). However, following high-temperature exposure in oxidative envi-ronments, aluminum is depleted from the coating. Aluminum depletion in turn, leads to de-stabilization of the Β phase, resulting in the formation of a characteristic lathlike Β-derivative microstructure. This article presents a transmission electron microscopy study of the formation of the lathlike Β-derivative microstructure using bulk nickel aluminides as model alloys. In the bulk nickel aluminides, the lathlike microstructure has been found to correspond to two distinct components: L10-type martensite and a new Β derivative. The new Β derivative is characterized and the conditions associated with the presence of this feature are identified and compared with those leading to the formation of the L10 martensitic phase. © 1995 The Minerals, Metals & Material Society.

Microstructural degradation of aluminide coatings on single crystal nickel based superalloys during high temperature exposure

An investigation, employing edge-on transmission electron microscopy, of the microstructure of aluminide diffusion coatings on a single crystal y' strengthened nickel base super alloy is reported. An examination has been made of the effect of postcoating exposure at 1100°C on the stability of the coating matrix, a B2 type phase, nominally NiAl. Precipitation in the coating is considered with respect to both decomposition of the B2 matrix to other Ni-Al (plus titanium) phases and the formation of chromium bearing precipitates. A comparison is drawn with behaviour at lower temperatures (850-950°C). © 1995 The Institute of Materials.