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

The recognition of the potential for enhanced fracture toughness that can be derived from controlled, stress-activated tetragonal (t) to monoclinic (m) transformation in ZrO2-based ceramics ushered in a new era in the development of the mechanical properties of engineering ceramics and provided a major impetus for broader-ranging research into the toughening mechanisms available to enhance the fracture properties of brittle-matrix materials. ZrO2-based systems have remained a major focal point for research as developments in understanding of the crystallography of the t→m transformation have led to more-complete descriptions of the origins of transformation toughening and definition of the features required of a transformation-toughening system. In parallel, there have been significant advances in the design and control of microstructure required to optimize mechanical properties in materials developed commercially. This review concentrates on the science of the t→m transformation in ZrO2 and its application in the modeling of transformation-toughening behavior, while also summarizing the microstructural control needed to use the benefits in ZrO2-toughened ceramics.

Transformation Toughening in Zirconia‐Containing Ceramics

Digital Image Correlation (DIC) is an important and widely used non-contact technique for measuring material deformation. Considerable progress has been made in recent decades in both developing new experimental DIC techniques and in enhancing the performance of the relevant computational algorithms. Despite this progress, there is a distinct lack of a freely available, high-quality, flexible DIC software. This paper documents a new DIC software package Ncorr that is meant to fill that crucial gap. Ncorr is an open-source subset-based 2D DIC package that amalgamates modern DIC algorithms proposed in the literature with additional enhancements. Several applications of Ncorr that both validate it and showcase its capabilities are discussed.

http://ncorr.com/download/publications/blaberncorr.pdf

Ncorr: Open-Source 2D Digital Image Correlation Matlab Software

Steels for bearings

The novel possibilities of phase feature detection in radiography at a third generation synchrotron radiation source are used to image, both in projection and in computed tomography, a cracked silicon single crystal and metal matrix composites strained in tension. Through an instrumentally very simple technique, based on Fresnel diffraction, phase jumps related to the interface between the matrix and the reinforcing phases of the composites are detected even when these phases show very similar x-ray attenuation. Strain-induced cracks with openings below the micrometer range are also visible through the phase modulation they introduce, illustrating the potential of the technique for assessing damage in materials with improved resolution and sensitivity.

Observation of microstructure and damage in materials by phase sensitive radiography and tomography

High temperature fatigue of nickel-base superalloys - A review with special emphasis on deformation modes and oxidation

This is an introductory text for materials science and engineering students. It takes an integrated approach to materials, with an organization focusing on properties rather than classes of materials.

The Science and Design of Engineering Materials

Low Cycle Fatigue (LCF) on smooth hour glass specimens and Fatigue Crack Propagation (FCP) studies on Single Edge Notch (SEN) specimens were carried out at room temperature on four Cu-Al polycrystalline alloys to investigate the effects of Stacking Fault Energy (SFE) and mechanical property variations on fatigue characteristics. Significant improvements in fatigue properties were observed for alloys of low SFE. A microhardness technique was used to delineate the fatigue plastic zone ahead of stopped cracks at several stress intensity ranges for all the alloys. Planar slip was associated with a less than a second power dependence of plastic zone size on the stress intensity range. Transmission Electron Microscopy (TEM) was used to observe the substructures that developed both in LCF at different strain ranges and also ahead of fatigue cracks at different stress intensity ranges. Fractography was carried out to study the micromechanisms of crack propagation using a two stage replication technique. The experimental results were in good agreement with a theoretical model for FCP developed previously by the authors which incorporates mechanical and microstructural variables.

Low cycle fatigue, fatigue crack propagation and substructures in a series of polycrystalline Cu-Al alloys

Interrupted tensile tests were conducted to fixed plastic strain levels in 100 ordered single crystals of the nickel based superalloy PWA 1480. Testing was done in the range of 20 to 1093 C, at strain rate of 0.5 and 50 percent/min. The yield strength was constant from 20 to 760 C, above which the strength dropped rapidly and became a strong function of strain rate. The high temperature data were represented very well by an Arrhenius type equation, which resulted in three distinct temperature regimes. The deformation substructures were grouped in the same three regimes, indicating that there was a fundamental relationship between the deformation mechanisms and activation energies. Models of the yielding process were considered, and it was found that no currently available model was fully applicable to this alloy. It was also demonstrated that the initial deformation mechanism (during yielding) was frequently different from that which would be inferred by examining specimens which were tested to failure.

Yielding and deformation behavior of the single crystal superalloy PWA 1480

Low cycle fatigue of Rene 80 was studied at 871 and 982 °C. It was found that when the data were represented on the basis of plastic strain, the life increased with decreasing frequency and imposition of a 90 s hold at maximum strain. Transmission electron microscopy studies showed that the ′ coarsened and an interfacial array of edge dislocations developed. The density of dislocations in the matrix was very low. Light optical microscopy revealed that cracks generally inititiated at oxide spikes in surface connected grain boundaries. A crack initiation criterion based on the maximum stress and oxide depth at the time of crack initiation was found to represent the data very well. Based on that representation, an expression for the initiation fatigue life was developed. That expression includes temperature, frequency and cyclic stress strain parameters as variables.

Stephen D. Antolovich

Papers

High temperature fatigue of nickel-base superalloys - A review with special emphasis on deformation modes and oxidation

The Science and Design of Engineering Materials

Low cycle fatigue, fatigue crack propagation and substructures in a series of polycrystalline Cu-Al alloys

Yielding and deformation behavior of the single crystal superalloy PWA 1480

Low cycle fatigue behavior of René 80 at elevated temperature