27 Super Alloy Case Study
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530.352 Materials Selection530.352 Materials Selection
Lecture #27: Superalloy Case StudyWednesday Nov 16th, 2005
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The Boeing 777The Boeing 777
Powered by two GE 90’s
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777’s are powered by 2 GE90’s:777’s are powered by 2 GE90’s:
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Low Pressure Turbine
High Pressure Turbine
Combustor
High Pressure Compressor
Low Pressure Compressoror Booster
Fan
Fan AirCoreAir
GE 90 Jet Engine :GE 90 Jet Engine :
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AEROTURBINE ENGINEAEROTURBINE ENGINE
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Efficiency of a heat engineEfficiency of a heat engine
1
21
T
TTEfficiency
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Three ways to increase efficiency:Three ways to increase efficiency:
TBC
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Improvements in superalloy creep strength:Improvements in superalloy creep strength:
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Improvements in creep strength:Improvements in creep strength:
Alloy development based on fundamental understanding of creep applied empirically.
Form stable precipitates (Ni3Al, Ni3Ti, M23C6, MoC, TaC)Have as many heavy atoms in solid solution as
possible (Hf, W, Co, Cr, Ta, etc.)Form a protective oxide surface (Cr2O3 or Al2O3)
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Improvements in creep strength:Improvements in creep strength:
10 m10 m
1 m1 m
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Solution Heat Treatment
Aging Treatment
Tem
pera
ture
Time
Tsolvus
Secondary ´
Tertiary ´Primary ´
• Supersolvus heat treatment (no “primary” ’)
• Secondary ’ develops upon cooling from supersolvus temperature
• Tertiary ’ forms upon cooling and subsequent aging
Microstructure development:Microstructure development:
Ref. Mills et alRef. Mills et al
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Superalloy developments:Superalloy developments:
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Improvements in creep strength:Improvements in creep strength:
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Changing grain size to mitigate creep:Changing grain size to mitigate creep:
EquiaxedEquiaxed
Directional solidificationDirectional solidification
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Single Single
crystal crystal turbine turbine bladeblade
Making single-crystalline turbine blades:Making single-crystalline turbine blades:
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Investment casting:Investment casting:
http://www.alcoa.com/howmet/en/info_page/inv_cast.asp# http://www.alcoa.com/howmet/en/info_page/inv_cast.asp#
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Section of a blade with cooling channels:Section of a blade with cooling channels:
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Internal cooling channels: casting:Internal cooling channels: casting:
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“TBCs are ‘bill-of-materials’ in many GEAE product lines: turbine blades, vanes, combustors.
Designers love it, and want more.”
Engine run without TBC
Engine run with TBC(150ºF reduction)
Ref. Ram Darolia, GE Aircraft Engines
Industrial perspective on the use of TBC’s:Industrial perspective on the use of TBC’s:
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Strengthening of Gamma TiAl: Pros and ConsStrengthening of Gamma TiAl: Pros and Cons
Curt Austin and Jim Williams
TMS Annual Meeting
San Antonio, TX
2/17/98
Aircraft Engines
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Outline of TalkOutline of Talk
Introduction to strengtheningDefinitionProperty correlations:
creep/yield strength; fatigue/yield strength; etc.Limitations, i.e. property trades & compromisesNeeds and applications
General discussion of strengthening of GammaMechanismsTrade-offsBenefits and “costs”
Consequences of strengthened GammaDuctilityFatigue strength
Summary and Conclusions
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StrengtheningStrengthening
Narrow Definition: Alterations in the composition and/or microstructure that increase the time independent flow stress at small plastic strain (the yield stress)
Broader Definition: Alterations in the composition and/or microstructure that increase the time dependent flow stress at small plastic strain (the creep strength)
The available mechanisms and opportunities for these two strengthening modes are quite different
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Effects Alloying on PropertiesEffects Alloying on Properties
DuctilityCr, Mn, V
Oxidation ResistanceCr, Nb, Ta, Zr
Tensile StrengthCr, Ta, W, B
Creep ResistanceCr, W, Ta, C, Si
Some alloying elements affect more than one property
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Strength ImprovementStrength Improvement
Not difficult to improve strength:
- mechanisms avail.
Improved strength with constant ductility very difficult (complex issue)
Kth increase also req’d. to realize full benefit
200
300
400
500
600
Yie
ld S
tren
gth
, M
Pa
0 0.5 1 1.5 2 2.5 3
Elongation
Exp Alloys48-2-2
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Available Strengthening MechanismsAvailable Strengthening Mechanisms
Solid solution Generally low solubility, second phases can be harmful Not a major contributor
Boundary Strongest contributor Can use heat treatment to tailor strength (within limits)
Texture (preferred orientation) Possible in principle for wrought products Difficult to control cost? Magnitude of effect not well-characterized
Second phase particle strengthening Relatively low Gfine dispersion for much strengthening Coarsening could be an issue
The real “player” is boundary strengthening
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Ductility Vs. Yield StrengthDuctility Vs. Yield Strength
Increasing Yield Strength has a large effect on ductility
f =
0
f
f
00
f
Str
ess
Strain
y
y
y
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Fracture Surfaces in Ti- 48.9% AlFracture Surfaces in Ti- 48.9% Al
Transgranular, interdendritic fracture mode
with B2(1.2 % elong.)
without B2(1.5% elong.)
B2
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Ductility of Gamma - IssuesDuctility of Gamma - Issues
Major negative distinction from conventional alloys Careful component selection eliminates this technical concern Still a psychological issue with designers
Requirement often not explicitly known See component selection above Useful for “margin” and “robustness”
Often implicitly required at stress concentrations Need enough to relax stress without crack initiation Very helpful in avoiding handling and impact damage
Explicitly required in a few components rotor overspeed relatively small amount required (but > 0 !!)
containment, applies to casing applications
Ductility is a bigger perceived than real issue
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Ductility as f(Al, dT/dt)Ductility as f(Al, dT/dt)
0.5
1
1.5
2
2.5
3%
Elo
ng
.
45 46 47 48 49
Al level, a/o
witness bars, fastest dT/dt
slabs, slower
slabs, faster
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Fracture as f(Al, dT/dt)Fracture as f(Al, dT/dt)
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Cr-Nb-Ta assessed effects on ductilityCr-Nb-Ta assessed effects on ductility
-0.3
-0.2
-0.1
0.0
0.1
0.2 D
elta
lo
g e
lon
g.
0 1 2 3 4Atomic percent
Cr
Ta
Nb
B2 ppts. interdendritic embritt.Interdendritic strengthening
Two distinct domains in cast alloys
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Yield Strength vs. HCF StrengthYield Strength vs. HCF Strength
Data for several alloys and several temperatures
0
20
40
60
80
0 20 40 60 80 100
0.2% Yield Strength, ksi
R = 0Alt
ern
atin
g s
tre
ss
(k
si)
@ 1
0 7 c
yc
les
R = -1
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Limiting Property Often KthLimiting Property Often Kth
Material 1: Lo fatigue strength, Baseline FCG, baseline Kth (4.35)Material 2: Hi fatigue strength, Baseline FCG, baseline Kth Material 3: Hi fatigue strength, Lower FCG (0.4x) , baseline Kth Material 4: Hi fatigue strength, Lower FCG (0.4x) , higher Kth (5.0)
Life (Cycles)
101
102
103
104
105
106
107
20
30
40
50
60
70M
ax. S
tres
s (k
si)
Material 4
th80
Materials 1,2, & 3
0.015” surface flaw
a
from Ken Wright, GE
Fat. Strength:Material 1Materials 2, 3 & 4
FCG:Material 1,2Material 3,4
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As-cast segregation patternAs-cast segregation pattern
Sutliffe, Huang and Sitzman
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NCG 359ENCG 359E
0.15% elong
47Al-1.8Cr-0.8Nb-1.7Ta 0.6% elong
High impurity heat
Low Al heat
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Speculation Regarding CreepSpeculation Regarding Creep
Alloying effects:Cr is potent strengthener
Strengthens gammaVery fine B2 ppts may be good
NbHeavy solute atom effect outweighed by reduced grain size
TaHeavy solute effect outweighs reduced grain size
Microstructure effects:Grain size is importantGrain aspect ratio may be importantSecond phase coarsening not well understood
Hard to separate composition and microstructure contributions
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Some Property CorrelationsSome Property Correlations
Direct correlations:Strength - HCF strength Strength -Partcost
Particularly true for wrought processing
Inverse correlations:Strength - Ductility Ductility -Crack growth Creep -Ductility
Caveat: Above observations colored by GE focus on
cast material, but: some very interesting wrought properties obtained recently GE following closely those related to components for which
wrought processing is amenable and affordable.
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Blade StatusBlade Status
Design releasedCasting trials nearing completionRisk issues under studyEconomical production is major
concern
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Summary and Take-awaysSummary and Take-aways
Strengthening of Gamma is possible: Standard mechanisms pertain (to varying degrees)
Increased strength hurts ductility: Component selection to minimize risk is essential Need to deal with perceived risk by designers Situation for cast and for wrought alloys may be different
Increased strength helps smooth fatigue but: Life benefit limited unless FCG rate and Kth can be
improved
Creep less well understood but relation to yield strength appears limited
Cast Gamma still most likely to be affordable Need to get one or two real service applications