Precipitation-controlled grain boundary engineering in a cast & wrought Ni-based superalloy

Abstract

Grain boundary engineering (GBE) describes the various approaches to control the fraction and composition of special boundaries in designing engineering materials. For example, complex thermo-mechanical processing routes are harnessed to increase the fraction of Σ3 twin boundaries, bringing about improvements to strength, toughness, and corrosion properties in austenitic stainless steels. However, high-temperature gas turbine engine components designed for the most demanding applications must be manufactured from Ni-based superalloys. To provide the required high-temperature strength, their microstructures are highly complex and consist of an austenitic γ-matrix, γ' precipitates, and grain boundary (GB) carbides, and/or borides. GBE approaches for Ni-based superalloys have been reported to reduce in-service GB cracking via targeted engineering of the GB microstructure. However, the same complex microstructures severely limit the processability of the most advanced Ni-based superalloys required to develop the next generation gas turbine engines.To tackle this challenge, we propose precipitation-controlled GBE for Ni-based superalloys with limited formability, via formation of GB serrations and precipitation upon slow cooling. We showcase our approach by achieving controlled GB precipitation of GB-γ' and M6C carbides in the cast & wrought Ni-based superalloy René 41 via a simple heat treatment. Ductility improvements are predicted via crystal plasticity modeling due to increased slip transmission compatibility. Instead of generating additional Σ3 twin boundaries only, these interfaces are directly incorporated into the GB network. It is shown that precipitation-controlled GBE is enabled by GB-γ' nucleating heterogeneously on M6C whereby competitive coarsening of GB-γ' provides the driving force. The fundamental mechanisms of our GBE approach are discussed and summarized in a qualitative microstructural model.