A consistent set of embedding functions and pair interactions for use with the embedded-atom method [M.S. Daw and M. I. Baskes, Phys. Rev. B 29, 6443 (1984)] have been determined empirically to describe the fcc metals Cu, Ag, Au, Ni, Pd, and Pt as well as alloys containing these metals. The functions are determined empirically by fitting to the sublimation energy, equilibrium lattice constant, elastic constants, and vacancy-formation energies of the pure metals and the heats of solution of the binary alloys. The validity of the functions is tested by computing a wide range of properties: the formation volume and migration energy of vacancies, the formation energy, formation volume, and migration energy of divacancies and self-interstitials, the surface energy and geometries of the low-index surfaces of the pure metals, and the segregation energy of substitutional impurities to (100) surfaces.

Embedded-atom-method functions for the fcc metals Cu, Ag, Au, Ni, Pd, Pt, and their alloys.

1. Introduction 2. The physical metallurgy of nickel and its alloys 3. Single crystal superalloys for blade applications 4. Superalloys for turbine disc applications 5. Environmental degradation: the role of coatings 6. Summary and future trends.

The Superalloys: Fundamentals and Applications

The chemical, physical, and mechanical characteristics of nickel-based superalloys are reviewed with emphasis on the use of this class of materials within turbine engines. The role of major and minor alloying additions in multicomponent commercial cast and wrought superalloys is discussed. Microstructural stability and phases observed during processing and in subsequent elevated-temperature service are summarized. Processing paths and recent advances in processing are addressed. Mechanical properties and deformation mechanisms are reviewed, including tensile properties, creep, fatigue, and cyclic crack growth. I. Introduction N ICKEL-BASED superalloys are an unusual class of metallic materials with an exceptional combination of hightemperature strength, toughness, and resistance to degradation in corrosive or oxidizing environments. These materials are widely used in aircraft and power-generation turbines, rocket engines, and other challenging environments, including nuclear power and chemical processing plants. Intensive alloy and process development activities during the past few decades have resulted in alloys that can tolerate average temperatures of 1050 ◦ C with occasional excursions (or local hot spots near airfoil tips) to temperatures as high as 1200 ◦ C, 1 which is approximately 90% of the melting point of the material. The underlying aspects of microstructure and composition that result in these exceptional properties are briefly reviewed here. Major classes of superalloys that are utilized in gas-turbine engines and the corresponding processes for their production are outlined along with characteristic mechanical and physical properties.

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Nickel-Based Superalloys for Advanced Turbine Engines: Chemistry, Microstructure and Properties

Creep deformation in 〈001〉 oriented nickel base superalloy single crystals has been studied in an effort to assess the factors which contribute to the overall creep resistance of superalloys with high volume fractions of γ′ phase. Detailed observations of three dimensional dislocation arrangements produced by creep have been made with the use of stereo electron microscopy. In the temperature range of 800–900°C at stresses of 552 MPa or lower, the dislocation-free γ′ precipitates are resistant to shearing by dislocations. As a result, creep deformation occurs by forced bowing of dislocations through the narrow γ matrix channels on {111} planes. At moderate levels of temperature and stress there are incubation periods in virgin crystals prior to the onset of primary creep. The incubations arise because of the difficult process of filling the initially dislocation starved material with creep dislocations from widely spaced sources. When the newly generated dislocations percolate through the cross section, incubation comes to an end and primary creep begins. In primary creep neither work hardening nor any type of recovery plays an important role. The creep rate decelerates because the favorable initial thermal misfit stresses between γ and γ′ phases are relieved by creep flow. Continued creep leads to a build-up of a three-dimensional nodal network of dislocations. This three-dimensional network fills the γ matrix channels during steady state creep and achieves a quasi-stationary structure in time. In situ annealing experiments show that static recovery is ineffective at causing rearrangements in the three-dimensional network at temperatures of 850°C or lower. The kinematical dislocation replacement processes which maintain the quasi-stationary dislocation network structures during apparent steady state creep are not understood and require further study. Because of the impenetrability of the γ′ precipitates, dislocations move through the γ matrix by forced Orowan bowing, and this accounts for a major component of the creep resistance. In addition, the frictional constraint of the coherent or semi-coherent precipitates leads to the build-up of pressure gradients in the microstructure, and this provides load carrying capacity. There is also a smaller component of solid solution strengthening. Work hardening is comparatively unimportant. Finite element analysis shows that the non-deforming precipitates are increasingly stressed as creep deformation accumulates in the matrix. In the later stages of steady state creep and during tertiary creep the stresses in the precipitates rise to high enough levels to cause shearing of the γ′ particles by dislocations entering from the γ matrix. The recovery resistance of the material is in part due to a very low effective diffusion constant and in another part due to the fact that the three-dimensional dislocation networks formed in the γ matrix serve to neutralize the misfit between the γ and γ′ phases.

Creep resistance of CMSX-3 nickel base superalloy single crystals

To obtain meaningful results from atomistic simulations of materials, the interatomic potentials must be capable of reproducing the thermodynamic properties of the system of interest. Pairwise potentials have known deficiencies that make them unsuitable for quantitative investigations of defective regions such as crack tips and free surfaces. Daw and Baskes [Phys. Rev. B 29, 6443 (1984)] have shown that including a local “volume” term for each atom gives the necessary many-body character without the severe computational dependence of explicit n-body potential terms. Using a similar approach, we have fit an interatomic potential to the Ni3Al alloy system. This potential can treat diatomic Ni2, diatomic Al2, fcc Ni, fcc Al and L12 Ni3Al on an equal footing. Details of the fitting procedure are presented, along with the calculation of some properties not included in the fit.

Accurate Interatomic Potentials for Ni, Al and Ni3Al

Anisotropic creep properties of the nickel-base superalloy CMSX-4

Finite element calculations were made in order to simulate coherency stresses in the commercial superalloy SRR 99 containing 70 vol.% of γ′ phase. Stress and strain energy properties are calculated for the relevant morphologies observed in SRR 99. The influence of 2D/3D and isotropic/anisotropic modelling on the results is discussed in detail. Our results are applied to better understand the high temperature evolution of the microstructure. The sphere to cube transition with increasing precipitate size and the appearance of butterfly distorted cubes during cooling will be discussed.

Modelling thermal misfit stresses in nickel-base superalloys containing high volume fraction of γ′ phase

Measurement of the lattice misfit in the single crystal nickel based superalloys CMSX-4, SRR99 and SC16 by convergent beam electron diffraction

Quenching experiments in high purity Ni

The microstructure of creep specimens tested at 1253 K is analyzed in the three stages of the creep curve by TEM investigations. Stage I is characterized by the glide of screw dislocations in the matrix, while the transition to stage II is the beginning of γ′ rafting. Throughout stage II, the γ′ phase is not cut by dislocations. From these and other metallographic results, the mechanism of creep in the single-crystal alloy can be deduced. The misfit stress at the γ/γ′ interfaces proved to be of special importance for this type of alloy containing a high volume fraction of γ′.

Monika Feller-Kniepmeier

Papers

Anisotropic creep properties of the nickel-base superalloy CMSX-4

Modelling thermal misfit stresses in nickel-base superalloys containing high volume fraction of γ′ phase

Measurement of the lattice misfit in the single crystal nickel based superalloys CMSX-4, SRR99 and SC16 by convergent beam electron diffraction

Quenching experiments in high purity Ni

Correlation of microstructure and creep stages in the 〈100〉 oriented superalloy SRR 99 at 1253 K