Superalloys 2016: proceedings of the 13th International Symposium on Superalloys ; sponsored by the Seven Springs International Symposium Committee in cooperation with the High Temperature Alloys Committee of the Structural Materials Division of TMS (The

1016 Pages·2016·327.696 MB·English

by  Mark C. Hardy, Eric S. Huron, Uwe Glatzel, Brian Griffin, Beth Lewis, Cathie Rae, Venkat Seetharaman, Sammy Tin

S U P E M L L O YS
2016
S U P E M L L O YS
2016
Proceedings of the
13th International Symposium
on Superalloys
Sponsored by
the Seven Springs International Symposium Committee in cooperation with the
High Temperature Alloys Committee of the Structural Materials Division of TMS
(The Minerals, Metals & Materials Society) and co-sponsored by ASM International
and IOM3 (The Institute of Materials, Minerals and Mining)
Held
September 11-15, 2016 at the Seven Springs Mountain Resort,
Seven Springs, Pennsylvania, USA
Edited by
Mark Hardy, Eric Huron, Uwe Glatzel, Brian Griffin, Beth Lewis, Cathie Rae,
Venkat Seetharaman, and Sammy Tin
TMS
Wl LEY
Copyright © 2016 by The Minerals, Metals & Materials Society.
All rights reserved.
Published by John Wiley & Sons, Inc., Hoboken, New Jersey.
Published simultaneously in Canada.
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10 98765432 1
Wl LEY TIMIS
TABLE OF CONTENTS
Superalloys 2016
Preface xiii
Dedication xv
Best Paper Award xv/'/'
Committee Members x/'x
Symposium Keynote Address
Innovation through Collaboration 3
S.J. Patel and J.J. deBarbadillo
Session 1: Alloy Development I
Alloys-by-Design: Towards Optimization of Compositions of Nickel-Based Superalloys 15
Roger C. Reed, Alessandro Mottura, and David J. Crudden
CMSX-4® Plus Single Crystal Alloy Development, Characterization and Application Development 25
Jacqueline B. Wahl and Ken Harris
Development of a Low-Density Rhenium-Free Single Crystal Nickel-Based Superalloy by Application of Numerical
Multi-Criteria Optimization Using Thermodynamic Calculations 35
RalfRettig, Kami I Matuszewski, Alexander Müller, HaraldE. Helmer, Nils C. Ritter, and Robert F. Singer
Investigation of Superalloy Composition Space Using High Throughput Thin Film Synthesis and Synchrotron X-Ray
Diffraction 45
L.D. Connor, P.M. Mignanelli, S. Guérin, J.P. Soulié, C. Mormiche, S. Frost, R. Greenhalgh, B.E. Hayden,
and H.J. Stone
Interactive Session A: Alloy Development II
Development of a Low-Cost Third Generation Single Crystal Superalloy DD9 57
J.R. Li, S.Z. Liu,X.G. Wang, Z.X. Shi, andJ.Q. Zhao
Grain Boundary Precipitation Strengthening of Phosphorus-Added Nickel-Iron Base Superalloy 65
Yusaku Hasebe, Koichi Takasawa, Takuya Ohkawa, Eiji Maeda, and Takashi Hatano
Development of New SX Superalloys - Fast Experimental Feedback Versus Thermodynamic Modeling 75
R. Võlkl, E. Fleischmann, R. Rettig, E. Affeldt, and U. Glatzel
Experimental Study of the Binary Ni-Ru-System Using Diffusion Couples Manufactured by Encapsulating Cast 83
Robert Popp, Rainer Võlkl, Thomas Gõhler, and Uwe Glatzel
The Role of Local Chemical Composition for TCP Phase Precipitation in Ni-Base and Co-Base Superalloys 89
T. Hammerschmidt, J. Kofimann, C.H. Zenk, S. Neumeier, M. Gõken, I. Lopez-Galilea, L. Mujica Roncery,
S. Huth, A. Kostka, W. Theisen, and R. Drautz
Precipitation Kinetic Modeling of the New Eta-Phase Ni AlNb in Ni-Base Superalloys 97
6
Markus Rath, Erwin Povoden-Karadeniz, and Ernst Kozeschnik
Development of Ni-Cr-Fe-W-Al Superalloy for Advanced Ultra-Supercritical Fossil Power Plants 107
X. C. Hao, M. Q. Ou, T. Liang, C. Xiong, Y. C. Ma, and K. Liu
Development of Low or Zero-Rhenium High-Performance Ni-Base Single Crystal Superalloys for Jet Engine and
Power Generation Applications 115
Kyoko Kawagishi, Tadaharu Yokokawa, Toshiharu Kobayashi, Yutaka Koizumi, Masao Sakamoto,
Michinari Yuyama, Hiroshi Harada, Lkuo Okada, Masaki Taneike, and Hidetaka Oguma
ν
Design of Next Generation Ni-Base Single Crystal Superalloys Containing Ir: Towards 1150 °C Temperature
Capability 123
T. Yokokawa, H. Harada, Y. Mori, K. Kawagishi, Y. Koizumi, T. Kobayashi, M. Yuyama, and S. Suzuki
Sulfur and Minor Element Effects on the Oxidation of Bilayer γ'+ β Bond Coats for Thermal Barrier Coatings on
René N5 131
David J. Jorgensen, Akane Suzuki, Don M. Lipkin, and Tresa M. Pollock
High Temperature Creep of γ'-Containing CoNi-Based Superalloys 141
Michael S. Titus, Luke H. Rettberg, and Tresa M. Pollock
Effects of Si Addition on the High Temperature Strength and Oxidation Behavior of γ'-Bearing Co-Based
Superalloys 149
An-Chou Yeh, L-Ting Ho, Sheng-Chi Wang, and Chia-Fu Cheng
The Effect of Alloying Elements on the High Temperature Oxidation of Solid-Solution Strengthened Ni-Base
Superalloys 159
Dae Won Yun, Y.S. Yoo, H.W. Jeong, and SM. Seo
Effect of Bond Coat and Substrate Chemistry on the Interfacial Degradation of Thermal Barrier Coatings 167
L. T. Wu, R. T. Wu, T. Osada, KL. Lee, Μ. Bai, and P. Xiao
Effect of Re and Ta on Hot Corrosion Resistance of Nickel-Base Single Crystal Superalloys 177
J.X. Chang, D. Wang, G. Zhang, L.H. Lou, and J. Zhang
Session 2: Alloy Development III
Advanced Supersolvus Nickel Powder Disk Alloy DOE: Chemistry, Properties, Phase Formations and Thermal
Stability 189
Andrew Powell, Ken Bain, Andrew Wessman, Daniel Wei, Timothy Hanlon, and David Mourer
Y Phase Instabilities in High Refractory Content γ Y Ni-Base Superalloys 199
Stoichko Antonov, Dieter Lsheim, David N. Seidman, Eugene Sun, Randolph C. Helmink, and Sammy Tin
Development of Nickel-Cobalt Base P/M Superalloys for Disk Applications 209
Y.F. Gu, T. Osada, Τ. Yokokawa, Η. Harada, and J. Fujioka
Superalloys for Advanced Energy Applications: Inconel Alloy 740H - A Case Study on International
Government-Industry-University Collaboration 217
John deBarbadillo, Brian Baker, andXishan Xie
Session 3: Blade Alloy Manufacture
Application and Validation of a Directional Solidification Model and Dendrite Morphology Criterion for Complex,
Single-Crystal Castings 229
J.D. Miller, K.J. Chaput, D.S. Lee, andM.D. Uchic
Innovations in Casting Techniques for Single Crystal Turbine Blades of Superalloys 237
Dexin Ma, Fu Wang, Qiang Wu, Samuel Bogner, and Andreas Bührig-polaczek
The Distribution and Retention of Yttrium and Lanthanum in Cast Single Crystal Superalloys 247
S.P. Leyland, LMEdmonds, S. Lrwin, C.N. Jones, A. Bhowmik, D. Ford, and C.M.F. Rae
Interactive Session B: Alloy & Component Manufacture I
Multiscale Modeling of Heat Treatment Processing for Single-Crystal Ni-Base Superalloys 259
Chen Shen, Akane Suzuki, and Douglas G. Konitzer
vi
Microstructure Instability of Ni-Base Single Crystal Superalloys during Solution Heat Treatment 267
N. D 'Souza, D. Welton, J. Kelleher, G.D. West, Z.H Dong, G. Brewster, and H.B. Dong
Development of Thermal Barrier Coating System Using EQ Coating for Advanced Single Crystal Superalloys 279
Kazuhide Matsumoto, Kyoko Kawagishi, and Hiroshi Harada
Effect of Rejuvenation Heat Treatment and Aging on the Microstructural Evolution in Rene N5 Single Crystal Ni
Base Superalloy Blades 285
Joydeep Pala, Dheepa Srinivasana, and Eric Cheng
The Formation Mechanism, Influencing Factors and Processing Control of Stray Grains in Nickel-Based Single
Crystal Superalloys 293
Yafeng Li, Lin Liu, Taiwen Huang, Dejian Sun, Jun Zhang, and Hengzhi Fu
Resonant Ultrasound Spectroscopy for Defect Detection in Single Crystal Superalloy Castings 303
B.R. Goodlet, L.H. Rettberg, and T.M. Pollock
Investigation of Oxide Bifilms in Investment Cast Superalloy IN100 313
M.A. Kaplan, R.K Guarriello, and G.E. Fuchs
A New Analysis of the Microstructure of Ni-Based Single-Crystal Superalloys: Relevant Topological Parameters
for Efficient Microstructural Modeling 323
M. Degeiter, M. Perrut, B. Appolaire, Y. Le Bouar, and A. Fine I
Single-Crystal Superalloy Joining 333
Akane Suzuki, Jeffrey Schoonover, Chen Shen, and David Wark
Selective Electron Beam Melting of the Single Crystalline Nickel-Base Superalloy CMSX-4®: From Columnar
Grains to a Single Crystal 341
Markus Ramsperger and Carolin Kòrner
Defect Formation and Its Mitigation in Selective Laser Melting of High γ' Ni-Base Superalloys 351
Xiqian Wang, Noriko Read, Luke N. Carter, R. Mark Ward,Moataz andM. Attallah
Developing Processing Parameters for Nickel-Base Superalloys for the Electron Beam Melting Additive
Manufacturing Process 359
Francisco Medina, Michael Kirka, UlfAckelid, and Ryan Dehoff
Parameter Optimization for Electron Beam Melting of IN718 Based on Melt Pool Characterization 367
Xiao Ding, Yuichiro Koizumi, andAkihiko Chiba
Effect of Heat Treatments on the Microstructure and Texture of CM247LC Processed by Selective Laser Melting 375
R. Muñoz-Moreno, V.D. Divya, OM.D.M. Messé, Τ. Lllston, S. Baker, and H.J. Stone
Session 4: Blade Alloy Behavior
Thermal Cycling Creep Resistance of Ni-Based Single Crystal Superalloys 385
Jonathan Cormier
Influence of Crystal Orientation on Cyclic Sliding Friction and Fretting Fatigue Behavior of Single Crystal Ni-Base
Superalloys 395
Balavenkatesh Rengara], Sotaro Baba, andMasakazu Okazaki
Sustained Peak Low-Cycle Fatigue in Single Crystals with Equilibrium γ-γ' Coatings 405
M.A. Lafata, L.H. Rettberg, C. Mercer, and T.M. Pollock
vii
Session 5: Disk Alloy Manufacture
Heteroepitaxial Recrystallization Observed in René 65™ and Udimet 720™: A New Recrystallization Mechanism
Possibly Occurring in All Low Lattice Mismatch γ-γ' Superalloys 417
Marie-Agathe Charpagne, Thomas Billot, Jean-Michel Franchet, and Nathalie Bozzolo
Systematic Evaluation of Microstructural and Thermo-Mechanical Effects on the As-Forged Condition of Alloy
ATI 718Plus® 427
Ana Casanova, Katja Loehnert, Daniela Huenert, Mark Hardy, and Catherine Rae
Effect of Ingot Size on Microstructure and Properties of the New Advanced AD730™ Superalloy 437
C. Croze t, A. Devaux, R. Forestier, S. Charmond, M. Hue Her, D. Helm, and W. Buchmann
Inhomogeneous Grain Coarsening Behavior in Supersolvus Heat Treated Nickel-Based Superalloy RR1000 447
IM.D. Parr, T.J. Jackson, M.C. Hardy, D.J. Child, C. Argyrakis, K. Severs, V. Saraf, andJ.M. Stumpf
Interactive Session C: Alloy & Component Manufacture II
The Influence of the Starting Grain Size during High-Temperature Grain Boundary Engineering of Ni-Base
Superalloy RR1000 459
Martin Detrois, John Rotella, Robert L. Goetz, Randolph C. Helmink, and Sammy Tin
Evaluation of AD730™ for High Temperature Fastener Applications 469
A. Devaux, W. Li, C. Crozet, and J.M. Lardón
Conventionally Forged RR1000 Billet for Forged Turbine Components 479
Kevin J. Bockenstedt, Christopher M. O 'Brien, Ramesh S. Minisandram, George J. Smith, and David J. Bryant
Deformation Mechanisms and Microstructural Evolution of γ + γ' Duplex Aggregates Generated during
Thermo mechanical Processing of Nickel-Base Superalloys 487
Beijiang Zhang, Guangpu Zhao, Wenyun Zhang, Guohua Xu, and Heyong Qin
Full Field Modeling of the Zener Pinning Phenomenon in a Level Set Framework - Discussion of Classical Limiting
Mean Grain Size Equation 497
B. Scholtes, D. Llin, A. Settefrati, N. Bozzolo, A. Agnoli, andM. Bernacki
Friction Stir Processing of Cast Alloy 718 505
Bharat K. Jasthi, Edward Chen, Brahmanandam Kaligotla, Todd Curtis, Michael West, and Christian Widener
Integrated Process Modeling for the Mechanical Properties Optimization of Direct Aged Alloy 718 Engine Disks 513
Bernd Oberwinkler, Andreas Fischersworring-Bunk, Marco Hüller, and Martin Stockinger
Influence of Carbide Distribution on Ductility of Haynes®282® Forgings 523
C. Joseph, M. Hòrnqvist, R. Brommesson, and C. Persson
An Approach to Microstructure Modelling in Nickel Based Superalloys 531
Aleksey Reshetov, Olga Bylya, Nicola Stefani, Malgorzata Rosochowska, and Paul Blackwell
Mechanical Properties of Cast & Wrought Hybrid Disks 539
Hesser Taboada Michel, Layla Sasaki Reda, Georgia Effgen Santos, Jonathan Cormier, Christian Dumont,
Patrick Villechaise, Philippe Bocher, Damien Texier, Eric Georges, Florent Bridier, Florence Hamon,
and Alexandre Devaux
viii
Session 6: Disk Alloy Behavior I
Separating the Influence of Environment from Stress Relaxation Effects on Dwell Fatigue Crack Growth in a
Nickel-Base Disk Alloy 551
J. Telesman, T.P. Gabb, and L.J. Ghosn
Microstructural Aspects of Fatigue Crack Initiation and Short Crack Growth in René 88DT 561
Zafir Alam, David Eastman, George Weber, Somnath Ghosh, and Kevin Hemker
Statistical Assessment of Fatigue-Initiating Microstructural Features in a Polycrystalline Disk Alloy 569
William C. Lenthe, Jean-Charles Stinville, McLean P. Echlin, and Tresa M. Pollock
Determination of Orientation and Alloying Effects on Creep Response and Deformation Mechanisms in Single
Crystals of Ni-Base Disk Superalloys 579
T.M. Smith, L. V. Duchao, T. Hanlon, A. Wessman, Y. Wang, and M.J. Mills
Session 7: Alloy & Component Manufacture III
High Temperature Properties of a Single Crystal Superalloy PWA1484 Directly Recycled after Turbine Blade Use 591
Satoshi Utada, Yuichiro Joh, Makoto Osawa, Tadaharu Yokokawa, Toshiharu Kobayashi, Kyoko Kawagishi,
Shinsuke Suzuki, and Hiroshi Harada
Manufacture of Large Ni-Base Ingots and Forgings 601
Nikolaus Blaes, Bernhard Donth, Andreas Diwo, and Dieter Bokelmann
Influence of Hot Working Conditions on Grain Growth Behavior of Alloy 718 609
Chuya Aoki, Tomonori Lleno, and Takehiro Ohno
Microstructure-Sensitive Model for Predicting Surface Residual Stress Relaxation and Redistribution in a P/M
Nickel-Base Superalloy 619
M.E. Burba, D.J. Buchanan, M.J. Catón, R. John, andRA. Brockman
Interactive Session D: Alloy & Component Behavior I
Fatigue Crack Growth Rate Assessment of Superalloys by the EBSD Method 631
D. Kobayashi, T. Takeuchi, andM. Achiwa
Stage I Fatigue Crack Propagation in a Single Crystal and a Directional Solidified Ni-Base Superalloy 639
Motoki Sakaguchi, Ryota Komamura, Yuta Hosaka, and Hirotsugu Lnoue
Anisothermal High-Temperature Cyclic Behavior of a Ni-Based Single Crystal Superalloy 647
Jean-Briac le Graverend, Jonathan Cormier, Franck Gallerneau, Serge Kruch, and José Mendez
Discussing the Effect of Gamma Prime Coarsening on High Temperature Low Stress Creep Deformation with
Respect to the Role of Refractory Elements 655
T. Goehler, C. Schwalbe, J. Svoboda, E. Affeldt, andR.F. Singer
On the Development of ICME Tools for Creep and Aging of CMSX®-8 665
E.A. Estrada Rodas, S. Gorgannejad, R. W. Neu, Z. Dyer, P.M. Draa, and S.R. Shinde
Creep Deformation of a 6th Generation Ni-Base Single Crystal Superalloy at 800 °C and 735 MPa 675
Y. Yuan, K. Kawagishi, Y. Koizumi, T. Kobayashi, T. Yokokawa, and H. Harada
Effect of Hf and Β on Transverse and Longitudinal Creep of a Re-Containing Nickel-Base Bicrystal Superalloy 683
Y.S. Zhao, J. Zhang, Y.S. Luo, G. Sha, D. Ζ. Tang, and Q. Feng
ix
Mechanical Properties and Microstructure Design in Repairing Mar-M 509 Alloy Turbine Components 693
Zengmei Wang Koenigsmann, Ravi Shankar, and Richard Fenton
Evaluation of Temperature and Stress in First Stage High Pressure Turbine Blades of a Directionally-Solidified
Superalloy DZ125 after Service in Aeroengines 701
Y.D. Chen, Y.R. Zheng, C.B. Xiao, and Q. Feng
On the Temperature Dependence of Creep Behavior of Ni-Base Single Crystal Superalloys 711
P. Wollgramm, X. Wu, and G. Eggeler
Microstructure Changes and Oxidation Resistance of Aluminized Ni-Based Single Crystal Superalloys 719
Hideyuki Murakami and Kazuki Kasai
Factors Affecting TBC Furnace Cycle Lifetime: Temperature, Environment, Structure and Composition 727
B.A. Pint, J A. Haynes, M.J. Lance, H.L. Aldridge, Jr., V. Viswanathan, G. Dwivedi, and S. Sampath
Oxidation Coating Life Extension in Gas Turbine Blades during Repair 735
Dheepa Srinivasan, N. Dayananda, Neha Kondekar, Mounika Gandi, and Hariharan Sundaram
Session 8: Blade Alloy Behavior II
High Temperature Creep Damage Mechanisms in a Directionally Solidified Alloy: Impact of Crystallography and
Environment 747
L. Mataveli Suave, J. Cormier, P. Villechaise, D. Bertheau, G. Benoit, F. Mauget, G. Cailletaud, and L. Marcin
Characterization of Tilt and Twist Low Angle Grain Boundaries and Their Effects on Intermediate-Temperature
Creep Deformation Behaviour 757
Yao Wang, Dong Wang, Gong Zhang, Langhong Lou, and Jian Zhang
Crack Initiation and Propagation during Thermal-Mechanical Fatigue of IN792: Effects of Dwell Time 763
Paraskevas Kontis, DavidM. Collins, Sten Johansson, Angus J. Wilkinson, Johan J. Moverare,
and Roger C. Reed
Creep and Oxidation Behaviour of Coated and Uncoated Thin Walled Single Crystal Samples of the Alloy
PWA1484 773
Fabian Krieg, Mike Mosbacher, Markus Fried, Ernst Affeldt, and Uwe Glatzel
Session 9: Disk Alloy Behavior II
ATI718Plus® - New Nickel Based Disc Alloy and Its Capability 783
D. Huenert, M. Proebstle, A. Casanova, R. Schluetter, R. Krakow, M. Buescher, P. Randelzhofer, A. Evans,
K. Loehnert, T. Witulski, S. Neumeier, and C. Rae
Thermal Stability of Cast and Wrought Alloy Rene 65 793
Andrew Wessman, Aude Laurence, Jonathan Cormier, Patrick Villechaise, Thomas Billot,
and Jean-Michel Franchet
Novel Techniques to Assess Environmentally-Assisted Cracking in a Nickel-Based Superalloy 801
André A.N. Németh, David J. Crudden, David M. Collins, David E.J. Armstrong, and Roger C. Reed
Interactive Session E: Alloy & Component Behavior II
Benchmarking Crystal Plasticity Models with Micro tensile Evaluation and 3D Characterization of René 88DT 813
David W. Eastman, Zafir Alam, George Weber, Paul A. Shade, Michael D. Uchic, William C. Lenthe,
Tresa M. Pollock, and Kevin J. Hemker
χ
Characterization and Modeling of Deformation Mechanisms in Ni-Base Superalloy 718 821
D. McAllister, D. Lv, H. Deutchman, B. Peterson, Y. Wang, and M.J. Mills
Dislocations Nucleation and Interaction with Grain Boundaries in a Polycrystalline Nickel Base Superalloy 831
O.M.D.M. Messé and C.M.F. Rae
Effect of Large Plastic Strains and Strain Gradients on Residual Stress Relaxation in Shot Peened IN100 841
Dennis J. Buchanan and Reji John
Relationship between the Microstructure, Low Cycle Fatigue and Creep Properties of a Cast and Wrought Ni-Co
Base Superalloy TMW-4M3 Disk 849
Shinichi Kobayashi, Tomonori Lleno, Takehiro Ohno, and Hiroshi Harada
Probability of Occurrence of Life-Limiting Fatigue Mechanism in P/M Nickel-Based Superalloys 859
S.K Jha, W.J. Porter, M.J. Catón, R. John, D.J. Buchanan, A.H. Rosenberger, andJ.M. Larsen
Influence of Residual Stresses on the Fatigue Life of a Shot-Peened Nickel-Based Single Crystal Superalloy: From
Measurements to Modeling 867
Amélie Morançais, Mathieu Fèvre, Manuel François, Nicolas Guel, Serge Kruch, Pascale Kanouté,
and Arnaud Longuet
Relationships between Microstructural Parameters and Time-Dependent Mechanical Properties of a New Nickel
Based Superalloy AD730™ 877
Louis Thébaud, Patrick Villechaise, Jonathan Cormier, Florence Hamon, Coraline Crozet, Alexandre Devaux,
Jean-Michel Franchet, Anne-Laure Rouffié, andAntoine Organista
A Unified LCF Model for Conventionally Heat Treated Inconel 718 887
Michael D. Marotta and David C. Dudzinski
Effect of Non-Metallic Ceramic Inclusions on Strain Localization during Low Cycle Fatigue of a Polycrystalline
Superalloy 897
Jean-Charles Stinville, Victoria M. Miller, and Tresa M. Pollock
Effects of Oxidation on Fatigue Crack Initiation and Propagation in an Advanced Disk Alloy 907
R. Jiang, N. Gao, Μ. Ward, Ζ. Aslam, J.C. Walker, and P.A.S. Reed
Physics-Based Modeling Tools for Predicting Type II Hot Corrosion in Nickel-Based Superalloys 917
KS. Chan, M.P. Enright, J.P. Moody, and S.H.K. Fitch
Characterization of Grain Boundaries and Associated Minor Phases in Disk Alloy ME3 Exposed at 815 °C 927
Chantal K. Sudbrack, Laura J. Evans, Anita Garg, Daniel E. Perea, and Daniel K. Schreiber
Session 10: Environmental Behavior
Slip Localization and Hydrogen Embrittlement of Alloy 718 939
Zhenbo Zhang, Gideon Obasi, Roberto Morana, and Michael Preuss
Effects of Sea Salt on the Oxidation of CMSX-4® at 1100 °C 949
Η. T. Pang, F. Li, S. Pahlavanyali, L.M. Edmonds, G. Brewster, and C.M.F. Rae
Damage Evolution during Compressive Hold Sustained Peak Low Cycle Fatigue of a Ni-Based Single-Crystal
Superalloy 959
Swapnil Patil, Shenyan Huang, Mallikarjun Karadge, Doug Konitzer, and Akane Suzuki
xi