Orientation Control for Nickel-Based Single Crystal Superalloys: Grain Selection Method Assisted by Directional Columnar Grains
<p>Schematic diagram of the grain selected method assisted by directional columnar grains: (<b>a</b>) the novel method; (<b>b</b>) the spiral selector used in this paper.</p> "> Figure 2
<p>The cross-sectional (<b>a</b>) and longitudinal sectional (<b>b</b>) microstructure of the directional columnar grains.</p> "> Figure 3
<p>The macrostructure of the adjusted grain selection process assisted by directional columnar grains: (<b>a</b>) a magnification view near melt-back region; (<b>b</b>) cross-sectional; (<b>c</b>) longitudinal (<b>d</b>) microstructure of casting.</p> "> Figure 4
<p>The statistical result of <001> direction of single crystal casting deviated from the directional solidification.</p> "> Figure 5
<p>The microstructure of the directional columnar grains after preparing single crystal casting: (<b>a</b>) the longitudinal microstructure, and the cross-section microstructures in (<b>b</b>) heat-affected zone I; (<b>c</b>) mushy zone II; (<b>d</b>) transition zone III; (<b>e</b>) directional growth zone IV.</p> "> Figure 6
<p>The metallographic microstructure and EBSD results detected by local area: (<b>a</b>) the longitudinal microstructure and EBSD maps and corresponding polar diagram tested in (<b>b1</b>,<b>b2</b>) zone 1, (<b>c1</b>,<b>c2</b>) zone 2, and (<b>d1</b>,<b>d2</b>) zone 3 in (<b>a</b>).</p> ">
Abstract
:1. Introduction
2. Experiment
3. Results
4. Discussion
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Conflicts of Interest
References
- Harris, K.; Erickson, G.L.; Schwer, R.E. Metals Handbook, 10th ed.; ASM Internationa: Material Park, OH, USA, 1990. [Google Scholar]
- Zhang, Y.; Qiu, W.; Shi, H.-J.; Li, C.; Kadau, K.; Luesebrink, O. Effects of secondary orientations on long fatigue crack growth in a single crystal superalloy. Eng. Fract. Mech. 2015, 136, 172–184. [Google Scholar] [CrossRef]
- Dong, H.B. Analysis of Grain Selection during Directional Solidification of Gas Turbine Blades. In Proceedings of the World Congress on Engineering 2007, London, UK, 2–4 July 2007; pp. 1257–1262. [Google Scholar]
- Stanford, N. Seeding of single crystal superalloys––Role of seed melt-back on casting defects. Scr. Mater. 2004, 50, 159–163. [Google Scholar] [CrossRef]
- Raza, M.H.; Wasim, A.; Hussain, S.; Sajid, M.; Jahanzaib, M. Grain Selection and Crystal Orientation in Single-Crystal Casting: State of the Art. Cryst. Res. Technol. 2019, 54, 1800177. [Google Scholar] [CrossRef]
- Zhang, H.; Zhu, X.; Wang, F.; Ma, D. 2-D Selector Simulation Studies on Grain Selection for Single Crystal Superalloy of CM247LC. Materials 2019, 12, 3829. [Google Scholar] [CrossRef] [Green Version]
- Gao, S.F.; Liu, L.; Wang, N.; Zhao, X.B.; Zhang, J.; Fu, H.Z. Grain Selection During Casting Ni-Base, Single-Crystal Superalloys with Spiral Grain Selector. Metall. Mater. Trans. A-Phys. Metall. Mater. Sci. 2012, 43, 3767–3775. [Google Scholar] [CrossRef]
- Zhu, X.; Yang, Q.; Wang, F.; Ma, D. Grain Orientation Optimization of Two-Dimensional Grain Selector during Directional Solidification of Ni-Based Superalloys. Materials 2020, 13, 1121. [Google Scholar] [CrossRef] [Green Version]
- Sadeghi, F.; Kermanpur, A.; Norouzi, E. Optimizing Grain Selection Design in the Single-Crystal Solidification of Ni-Based Superalloys. Cryst. Res. Technol. 2018, 53, 1800108. [Google Scholar] [CrossRef]
- Wang, N.; Liu, L.; Gao, S.; Zhao, X.; Huang, T.; Zhang, J.; Fu, H. Simulation of grain selection during single crystal casting of a Ni-base superalloy. J. Alloys Compd. 2014, 586, 220–229. [Google Scholar] [CrossRef]
- Seo, S.-M.; Kim, I.-S.; Lee, J.-H.; Jo, C.-Y.; Miyahara, H.; Ogi, K. Grain structure and texture evolutions during single crystal casting of the Ni-base superalloy CMSX-4. Met. Mater. Int. 2009, 15, 391–398. [Google Scholar] [CrossRef]
- Meng, X.; Li, J.; Jin, T.; Sun, X.; Sun, C.; Hu, Z. Evolution of Grain Selection in Spiral Selector during Directional Solidification of Nickel-base Superalloys. J. Mater. Sci. Technol. 2011, 27, 118–126. [Google Scholar] [CrossRef]
- Rappaz, M.; Gandin, C.A.; Desbiolles, J.L.; Thévoz, P. Prediction of grain structures in various solidification processes. Metall. Mater. Trans. A 1996, 27, 695–705. [Google Scholar] [CrossRef]
- Li, J.; Wang, Z.; Wang, Y.; Wang, J. Phase-field study of competitive dendritic growth of converging grains during directional solidification. Acta Mater. 2012, 60, 1478–1493. [Google Scholar] [CrossRef]
- Liu, J.-l.; Jin, T.; Luo, X.-h.; Feng, S.-b.; Zhao, J.-z. Effects of Solidification Conditions on the Crystal Selection Behavior of an Al Base Alloy During Directional Solidification. Microgravity Sci. Technol. 2016, 28, 109–113. [Google Scholar] [CrossRef]
- Zhang, X.; Zhou, Y.; Jin, T.; Sun, X.; Liu, L. Effect of Solidification Rate on Grain Structure Evolution During Directional Solidification of a Ni-based Superalloy. J. Mater. Sci. Technol. 2013, 29, 879–883. [Google Scholar] [CrossRef]
- Rezaei, M.; Kermanpur, A.; Sadeghi, F. Effects of withdrawal rate and starter block size on crystal orientation of a single crystal Ni-based superalloy. J. Cryst. Growth 2018, 485, 19–27. [Google Scholar] [CrossRef]
- Arakere, N.K.; Swanson, G. Effect of Crystal Orientation on Fatigue Failure of Single Crystal Nickel Base Turbine Blade Superalloys. J. Eng. Gas Turbines Power 2002, 124, 161–176. [Google Scholar] [CrossRef] [Green Version]
- Qiu, W.; He, Z.; Fan, Y.-N.; Shi, H.-J.; Gu, J. Effects of secondary orientation on crack closure behavior of nickel-based single crystal superalloys. Int. J. Fatigue 2016, 83, 335–343. [Google Scholar] [CrossRef]
- Yang, Z.; Chen, H.; Cao, J.; Zheng, S.; Luo, K.; Luo, Y.; Dai, S. A Novel Grain Selection Method Assisted by Columnar Grains for Ni-based Single Crystal Superalloy. Fail. Anal. Prev. 2021, 16, 173–176, 196. [Google Scholar]
- Hu, S.; Yang, W.; Li, Z.; Xu, H.; Huang, T.; Zhang, J.; Su, H.; Liu, L. Formation mechanisms and control method for stray grains at melt-back region of Ni-based single crystal seed. Prog. Nat. Sci.-Mater. Int. 2021, 31, 624–632. [Google Scholar] [CrossRef]
- Hu, S.; Liu, L.; Yang, W.; Sun, D.; Huo, M.; Li, Y.; Huang, T.; Zhang, J.; Su, H.; Fu, H. Inhibition of stray grains at melt-back region for re-using seed to prepare Ni-based single crystal superalloys. Prog. Nat. Sci.-Mater. Int. 2019, 29, 582–586. [Google Scholar] [CrossRef]
- Aveson, J.W.; Tennant, P.A.; Foss, B.J.; Shollock, B.A.; Stone, H.J.; D’Souza, N. On the origin of sliver defects in single crystal investment castings. Acta Mater. 2013, 61, 5162–5171. [Google Scholar] [CrossRef]
- Li, Y.; Liu, L.; Huang, T.; Zhang, J.; Fu, H. The process analysis of seeding-grain selection and its effect on stray grain and orientation control. J. Alloys Compd. 2016, 657, 341–347. [Google Scholar] [CrossRef]
- Walton, D.; Chalmer, B. The origin of the preferred orientation in the columnar zone of ingots. Trans. Metall. Soc. AIME 1959, 215, 447–457. [Google Scholar]
- Yang, C.; Liu, L.; Zhao, X.; Wang, N.; Zhang, J.; Fu, H. Competitive grain growth mechanism in three dimensions during directional solidification of a nickel-based superalloy. J. Alloys Compd. 2013, 578, 577–584. [Google Scholar] [CrossRef]
- Clarke, A.J.; Tourret, D.; Song, Y.; Imhoff, S.D.; Gibbs, P.J.; Gibbs, J.W.; Fezzaa, K.; Karma, A. Microstructure selection in thin-sample directional solidification of an Al-Cu alloy: In situ X-ray imaging and phase-field simulations. Acta Mater. 2017, 129, 203–216. [Google Scholar] [CrossRef] [Green Version]
- Wang, H.; Zhang, X.; Meng, J.; Yang, J.; Yang, Y.; Zhou, Y.; Sun, X. A new model of competitive grain growth dominated by the solute field of the Nickel-based superalloys during directional solidification. J. Alloys Compd. 2021, 873, 159794. [Google Scholar] [CrossRef]
- Yang, W.; Hu, S.; Huo, M.; Sun, D.; Zhang, J.; Liu, L. Orientation controlling of Ni-based single-crystal superalloy by a novel method: Grain selection assisted by un-melted reused seed. J. Mater. Res. Technol. 2019, 8, 1347–1352. [Google Scholar] [CrossRef]
- Hu, S.; Zhao, Y.; Bai, W.; Wang, X.; Yin, F.; Yang, W.; Liu, L. Temperature Field Evolution of Seeding during Directional Solidification of Single-Crystal Ni-Based Superalloy Castings. Metals 2022, 12, 817. [Google Scholar] [CrossRef]
Element | Cr | Co | W | Mo | Re | Al | Ti | Ta | Nb | C | Hf | B | Ni |
---|---|---|---|---|---|---|---|---|---|---|---|---|---|
DZ125 | 8.9 | 10.0 | 7.0 | 2.0 | - | 5.2 | 0.9 | 3.8 | - | 0.1 | 1.5 | 0.015 | Bal. |
DD6 | 4.3 | 9.0 | 8.0 | 2.0 | 2.0 | 5.6 | - | 7.5 | 0.5 | - | 0.1 | - | Bal. |
Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. |
© 2022 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
Share and Cite
Hu, S.; Zhao, Y.; Bai, W.; Dai, Y.; Yang, Z.; Yin, F.; Wang, X. Orientation Control for Nickel-Based Single Crystal Superalloys: Grain Selection Method Assisted by Directional Columnar Grains. Materials 2022, 15, 4463. https://doi.org/10.3390/ma15134463
Hu S, Zhao Y, Bai W, Dai Y, Yang Z, Yin F, Wang X. Orientation Control for Nickel-Based Single Crystal Superalloys: Grain Selection Method Assisted by Directional Columnar Grains. Materials. 2022; 15(13):4463. https://doi.org/10.3390/ma15134463
Chicago/Turabian StyleHu, Songsong, Yunsong Zhao, Weimin Bai, Yilong Dai, Zhenyu Yang, Fucheng Yin, and Xinming Wang. 2022. "Orientation Control for Nickel-Based Single Crystal Superalloys: Grain Selection Method Assisted by Directional Columnar Grains" Materials 15, no. 13: 4463. https://doi.org/10.3390/ma15134463