Secondary Reaction Zone Formations in coated Ni-base Single Crystal Superalloys

Abstract

Ruthenium (Ru) has been added to the latest 4th Generation Ni-base superalloys to improve phase stability and modify creep life. Various coatings are routinely applied to these advanced alloys to protect the turbine blade at elevated temperature, however, this creates several problems such as the precipitation of brittle Topologically Close-Packed (TCP) phases and the formation of Secondary Reaction Zones (SRZ). The SRZ forms under the plat-aluminized coating of turbine blades and consists of γ, γ and TCP phases growing into substrate by the migration of high-angle grain boundaries. Surface residual stress and chemical super-saturation of alloying elements are associated to SRZ formation. In the thin sections of high-pressure turbine blades this is critical in determining blade performance and longevity. It is essential to know how Ru additions affect coating and SRZ morphologies during exposure. In this study, we focus on the effects of three variables on the SRZ formation: Ru concentration, alloy composition in Ru-containing alloys and surface finish. A series of Platinum-Aluminised superalloys containing 2–5wt% Ru and having various surface finishes was studied after isothermal exposure at 1100°C for up to 500h. The alloys were classified into two groups by their distinctive SRZ morphology. At the lowest Ru levels sporadic formation of SRZ was observed, whilst a continuous SRZ was formed in the higher Ru alloys. EBSD analysis revealed that the latter group have a higher nucleation rate of individual SRZ grains and also showed more rapid SRZ growth. The precipitation of TCPs in the substrate also inhibited the growth of the SRZ towards the end of the exposure further reducing the penetration of the SRZ into the substrate. It is concluded that Ru-additions to Ni-base superalloys are effective in impeding TCP phase formation in the substrate, but increase both the extent and the rate of SRZ formation beneath coating.