Effect of phosphorus content and grain size on the long-term phase stability of Ni-base superalloys

Abstract

The effect of grain size on the phase stability of two nominally identical high refractory content powder-processed Ni-base superalloy with varying levels of P additions (0.013 wt% for alloy P1 and 0.026 wt% for alloy P3) was studied. Solutioning of the alloys at either sub-solvus or super-solvus temperatures were used to vary the grain size of the starting microstructure prior to long-term thermal exposures at 800 °C for up to 1000 h. EBSD analyses revealed that the sub-solvus solutioned samples had an average grain size of 10 μm and possessed a high angle grain boundary length density that was approximately 2.5 times greater than that found in the super-solvus solutioned samples with an average grain size of 16 μm. Differences in both the initial grain boundary character distribution and P content present in these alloys resulted in varying behavior with respect to the grain boundary precipitation of Laves and sigma phase during aging. Since P additions to Ni-base superalloys are known to promote the formation of Laves phases and segregate predominately to grain boundaries, sub-solvus heat treated samples exhibited a lower susceptibility of Laves phase precipitation compared with super-solvus heat treated samples for both P1 and P3 alloys. Sub-solvus heat treated P1 samples were found to be resistant to the formation of Laves phase after 1000 h exposure while the coarser grained super-solvus heat treated P3 samples exhibited extensive formation of intertwined Sigma-Laves along the grain boundaries just after 100 h exposure. The improvement in phase stability could be attributed to the reduced concentration of P along the grain boundary as increasing the length density of random high-angle grain boundary resulted in a more dilute spatial distribution of segregated P atoms.