Single Crystal Solidification Research Articles

Analysis of a Single Crystal Solidification Process of an Ni-based Superalloy using a CAFE Model

The efficiency of gas turbines depends on the gas turbine working temperature. Single crystal blades are being applied more often than equiaxed blades in gas turbine engines, to increase the turbine inlet temperature, resulting in enhanced turbine engine efficiency. Single crystal blades endure creep conditions at high temperature better than polycrystal blades because the single crystals do not include grain boundaries. The single crystal process is a breakthrough technology, however, production yield is relatively low compared with polycrystal, and their mechanical properties depend on the crystallographic orientation of the single crystals. In this study, a thermal simulation model, the 3D cellular automation-finite element (CA-FE), was used on the single crystal process with the Bridgman method. The simulation model was well expected, by analysis of the microstructure and EBSD, on the grain selection in the single crystal process. The evolution of single crystal grains was analyzed on process of grain selection in start block and spiral selector. Single crystal orientation was also investigated to determine the effect of nucleation density, forming in the initial stage of solidification.

Numerical Analysis of Stray Grain Formation during Laser Welding Nickel-Based Single-Crystal Superalloy Part III: Crystallography-Dependent Solidification Behavior

The solidification temperature range was numerically analyzed to optimize nonequilibrium solidification behavior during ternary Ni-Cr-Al nickel-based single-crystal superalloy weld pool solidification with variation of laser welding conditions (either heat input or welding configuration). The distribution of solidification temperature range along the fusion boundary is beneficially symmetrical about the weld pool centerline in the (001)/[100] welding configuration. The distribution of solidification temperature range along the fusion boundary is detrimentally asymmetrical about the weld pool centerline in the (001)/[110] welding configuration. The stray grain formation and solidification cracking are preferentially confined to [100] dendrite growth region. [001] epitaxial growth region with columnar dendrite morphology is favored at the expense of undesirable [100] growth region with equiaxed dendrite morphology to facilitate essential single-crystal solidification with considerable reduction of heat input. The smaller heat input is used, the narrower solidification temperature range is thermodynamically promoted to reduce nucleation and growth of stray grain formation with decrease of constitutional undercooling ahead of dendrite tip and mitigate thermo-metallurgical factors for morphology instability and microstructure anomalies. Potential low heat input(both decreasing laser power and increasing welding speed) with (001)/[100] welding configuration decreases solidification temperature range to significantly minimize columnar/equiaxed transition (CET) and stray grain formation, and improve resistance to solidification cracking through microstructure control. On both sides of weld pool are imposed by the same heat input, while the solidification temperature range along the fusion boundary inside of [100] dendrite growth region on the right part of the weld pool is spontaneously wider than that of [010] dendrite growth region on the left part to increase solidification cracking susceptibility in the (001)/[110] welding configuration. Furthermore, another mechanism of solidification cracking as consequence of severe solidification behavior and anomalous microstructure with asymmetrical crystallographic orientation is therefore proposed. The theoretical predictions are well verified by experiment results. The useful and satisfactory numerical modeling is also available for other single-crystal superalloys during successful laser repair process without stray grain formation.

Numerical Analysis of Aerospace Nickel-Based Single-Crystal Superalloy Weldability Part I: Crystallography-Dependent Dendrite Growth

The thermal-metallurgical modeling of microstructure development was further advanced during single-crystal superalloy weld pool solidification by coupling of heat transfer model, columnar/equiaxed transition (CET) model and multicomponent dendrite growth model on the basis criteria of minimum dendrite velocity, constitutional undercooling and marginal stability of planar front. It is clearly indicated that heat input (laser power and welding speed) and welding configuration simultaneously influence the stray grain formation, columnar/equiaxed transition and dendrite growth. For beneficial (001) and [100] welding configuration, the microstructure development along the solid/liquid interface is symmetrically distributed about the weld pool centerline throughout the weld pool. Finer columnar in [001] epitaxial dendrite growth region is kinetically favored at the bottom of the weld pool. For detrimental (001) and [110] welding configuration, the microstructure development along the solid/liquid interface is asymmetrically distributed. The dendrite trunk spacing along the solid/liquid interface from the beginning to end of solidification morphologically increases on the left side of the weld pool, while it spontaneously decreases on the right side. The vulnerable location of solidification cracking is confined in the [100] dendrite growth region on the right side of the weld pool because of increasing metallurgical contributing factors of severe stray grain formation, centerline grain boundary formation and coarse dendrite size. The mechanism of crystallography-dependent asymmetrical solidification cracking due to microstructure anomalies is proposed. It is crystallographically favorable for predominant morphology instability to deteriorate weldability. Active [100] dendrite growth region is diminished in the shallow elliptical weld pool by optimum low heat input (low laser power and high welding speed) with (001) and [100] welding configuration to essentially facilitate single-crystal solidification conditions and provide enough resistant to solidification cracking. Moreover, the theoretical predictions agree well with the experiment results. The reliable weldability maps are therefore established to determine the prerequisite for successful crack-free laser welding or cladding. The useful model is also applicable for other single-crystal superalloys with similar metallurgical properties.

DenMap single crystal solidification structure feature extraction: Automation and application

A fully automatic, standardised, and validated dendritic core detection algorithm, DenMap, is applied to analyse CMSX-4® and CMSX-10® single crystal microstructure. Through the utilisation of novel imaging techniques such as Gaussian deconvolution and minimisation-based thresholding, the newly enhanced version of DenMap demonstrates a significant improvement in detection accuracy and range of applications. The results indicate dendrites preferentially form channels, with array disorder increasing with height from the chill plate. A new twisting phenomenon has been observed that may have significant impact on the development of low and high angle grain boundaries and porosity formation within the microstructure. DenMap provides the foundation for 3D reconstruction methodologies and advanced pattern recognition techniques. This new standardised approach will facilitate the development of machine learning algorithms and eventually AI for single crystal solidification studies, particularly for the purpose of process optimisation.

Grain Optimization: Optimizing Grain Selection Design in the Single-Crystal Solidification of Ni-Based Superalloys (Crystal Research and Technology 12/2018)

Crystal Research and TechnologyVolume 53, Issue 12 1870022 Cover PictureFree Access Grain Optimization: Optimizing Grain Selection Design in the Single-Crystal Solidification of Ni-Based Superalloys (Crystal Research and Technology 12/2018) First published: 13 December 2018 https://doi.org/10.1002/crat.201870022AboutPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShare Give accessShare full text accessShare full-text accessPlease review our Terms and Conditions of Use and check box below to share full-text version of article.I have read and accept the Wiley Online Library Terms and Conditions of UseShareable LinkUse the link below to share a full-text version of this article with your friends and colleagues. Learn more.Copy URL Share a linkShare onFacebookTwitterLinkedInRedditWechat Graphical Abstract This figure represents selection phenomenon of single crystal during directional solidification. The process begins by arbitrarily nucleation of equiaxed grains at the copper chill contact area. Further progress of solidification brings about a columnar structure which is accompanied by competitive grain growth. A single grain finally encompass the upper part after solidification of spiral grain selector has come to an end. More details can be found in article number 1800108 by Fazlollah Sadeghi, Ahmad Kermanpur, and Ebrahim Norouzi. Volume53, Issue12December 20181870022 RelatedInformation

Temperature evolution and grain defect formation during single crystal solidification of a blade cluster

In order to investigate the asymmetry of thermal conditions during directional solidification, the temperature evolution and correspondingly developed undercooling in a simplified single crystal blade cluster were numerically simulated. Simulation results demonstrate that the temperature distribution at the blade platforms is obviously asymmetrical. On the outside of the blade which directly faces the heating element, the liquidus (TL) isotherms progress relatively smoothly. On the inside of the blades facing the central rod, however, the TL-isotherms are in concave shape and the slope goes upwards to the platform extremities. The average undercooling extent ΔT and undercooling time Δt at the inside are much higher than those at the outside. It was then predicted that the inside platform extremities have significantly higher probabilities of stray grain formation compared to the outside ones. A corresponding experiment was carried out and the metallographic examination exhibited the same side- and height-dependence of stray grain formation in the blades as predicted. On the inside of the blades, all platforms are occupied by stray grains, while the platforms on the outside are nearly stray grain free. The simulation result agrees very well with the experimental observation.

Laser Cladding for Crack Repair of CMSX-4 Single-Crystalline Turbine Parts

The increase of the lifetime of modern single crystalline (SX) turbine blades is of high economic priority. The currently available repair methods using polycrystalline cladding of the damaged area do not address the issue of monocrystallinity and are restricted to few areas of the blade. The tip area of the blade is most prone to damage and undergoes the most wear, erosion and cracking during its lifetime. To repair such defects, the common procedure is to remove the whole tip with the damaged area and rebuild it by applying a polycrystalline solidification of the material. The repair of small cracks is conducted in the same way. To reduce repair cost, the investigation of a manufacturing process to repair these cracked areas while maintaining single-crystal solidification is of high interest as this does not diminish material properties and thereby its lifetime. To establish this single-crystal solidification, the realization of a directed temperature gradient is needed. The initial scope of this work is the computational prediction of the temperature field that arises and its verification during the process. The laser cladding process of CMSX-4 substrates was simulated and the necessary parameters calculated. These parameters were then applied to notched substrates and their microstructures analyzed. Starting with a simulation of the temperature field using ANSYS®, a process to repair parts of single crystalline nickel-based alloys was developed. It could be shown that damages to the tip area and cracks can be repaired by establishing a specific temperature gradient during the repair process in order to control the solidification process.

Single-crystal solidification of new Co–Al–W-base alloys

Solidification processing of new high-temperature Co–Al–W-base single-crystals has been investigated. Single-crystal bars with compositions of Co–9.4Al–10.7W, Co–8.8Al–9.8W–2Ta and Co–7.8Al–7.8W–1.5Ta–4.5Cr (at%) were successfully grown with a conventional Bridgman process. Helical grain selectors resulted in [001] dendritic growth with primary dendrite arm spacings in the range of 278–364 μm. Segregation of constituent elements in the dendritic structure was very limited, compared to Ni-base single-crystals. Concentration profiles obtained by electron microprobe and analyzed via the Scheil equation indicate distribution coefficients for Co, Al, W and Cr that are close to 1. The distribution coefficient of Ta was approximately 0.6, indicating preferential segregation to the liquid during solidification. These observations collectively suggest that convective instabilities and freckle formation are unlikely to occur during solidification of single-crystals of this new class of high strength Co–Al–W-base alloys.

Development of heat conductor technique for single crystal components of superalloys

A new heat conductor (HC) technique was developed to minimise stray grain formation arising from the geometrical effect during single crystal solidification of superalloys. Graphite is recommended as HC material because of its excellent thermophysical properties. Computer simulation and temperature measurements have shown that this technique is able to produce a clear improvement of thermal condition in the critical region of the components. Both the extent and the period of undercooling at the platform extremity significantly decreased. Structural investigation revealed a notable reduction in stray grain quota, providing evidence for the effectiveness of the HC technique for improving the quality of single crystal components.

Avoiding grain defects in single crystal components by application of a heat conductor technique

Abstract During single crystal solidification in turbine blades, grain defects are often formed in the platform region with abrupt variation in cross-section. In order to reduce grain defects arising from component geometries an HC (Heat Conductor) technique was developed. In the production process for ceramic shell moulds, a graphite heat conductor of excellent heat conductivity is inserted close to the inner corner of the platform. This effectively extracts local heat from this critical region during directional solidification. Numerical simulations show that by using HC the thermal condition in the platform region can be significantly improved. The single crystal growth in the blade body can spread into the platform more quickly before the melt at the platform extremity becomes deeply undercooled. Structural investigations reveal a remarkable reduction in grain defect formation, providing confirmation of the effectiveness of the HC technique in improving the casting quality of single crystal components.

The Synthesis and Structures of Elpasolite Halide Scintillators

AbstractLow-cost, high-performance gamma-ray spectrometers are urgently needed for nonproliferation and homeland security applications. Available scintillation materials fall short of the requirements for energy resolution and sensitivity at room temperature. The emerging lanthanide halide based materials, while having the desired luminosity and proportionality, have proven difficult to produce in the large sizes and low cost required due to highly anisotropic properties caused by the non-cubic crystal structure. New cubic materials, such as the recently discovered elpasolite family (A2BLnX6; Ln-lanthanide and X-halogen), hold promise for scintillator materials due to their high light output, proportionality, and toughness. The isotropic nature of the cubic elpasolites leads to minimal thermomechanical stresses during single-crystal solidification, and eliminates the problematic light scattering at the grain boundaries. Therefore, it may be possible to produce these materials in large sizes as either single crystals or transparent ceramics with high production yield and reduced costs. In this study, we investigated the “cubic” elpasolite halide synthesis and studied the structural variations of four different compounds, including Cs2NaLaBr6, Cs2LiLaBr6, Cs2NaLaI6, and Cs2LiLaI6. Attempts to produce a large-area detector by a hot forging technique were explored.

Soldification segregation in ruthenium-containing nickel-base superalloys

Ruthenium-containing multicomponent Ni-base superalloys with large variations in refractory alloying elements (Re, Ru, Ta, and W) have been investigated with respect to solidification, segregation characteristics, and the tendency to develop grain defects during directional solidification. Phase transformation temperatures and the effects of alloy composition on the liquidus temperature were determined by differential thermal analysis (DTA). The liquidus temperatures for most Ru-containing superalloys are generally higher than those of current commercial single-crystal superalloys. The partitioning behavior of individual constituents under the influence of alloy chemistry was characterized using a quantitative segregation mapping technique combined with a Scheil-type analysis. Whereas ruthenium partitioned preferentially to the dendrite cores during soldification, segregation of Ru is much less pronounced than Re and W. A higher degree of rhenium segregation was observed in Ru-containing superalloys. For the fixed processing conditions and moderate levels of Ru+Re, single-crystal solidification occurred without freckle formation or convection-induced breakdown of the solidification front. However, with high levels of Ru (9.6 ∼ 14.1 wt pct) and Re (7.2 wt pct), grain defects or the complete breakdown of single-crystal solidification was observed. Results from segregation and DTA analyses were used to estimate the corresponding Rayleigh numbers present during solidification of the experimental alloys. The Rayleigh criterion is effective for predicting the conditions under which the grain defect formation occurs during directional solidification of Ru-containing superalloys.

A castability model based on elemental solid-liquid partitioning in advanced nickel-base single-crystal superalloys

A castability model that accounts for the characteristic segregation behavior of constituent elements in Ni-base superalloys has been developed and experimentally verified in production scale casting trials. The model ranks alloy compositions with respect to their susceptibility to freckle formation during directional solidification. Thirty-nine distinct Ni-base single-crystal superalloys encompassing a broad range of compositions were investigated to assess the influence of the constituent elements on their solidification characteristics. Linear regression was applied to the fitted solid-liquid partition coefficients of the major constituent elements to develop formulas capable of describing elemental interactions. The high-density refractory elements Ta, W, and Re were found to segregate most severely during solidification. Increasing the amount of Cr and Mo in high-refractory single-crystal alloys reduced the extent of W and Re microsegregation during solidification. This effect was found to minimize the occurrence of freckle defects due to the corresponding decrease in the density inversion term, which is effectively the driving force for thermosolutal convective instabilities known to cause macroscopic grain defects during single-crystal solidification. Model predictions were validated using production scale casting trials where additions of 1.5 wt pct (1.9 at. pct) Cr and 3.0 wt pct (2.0 at. pct) Mo to a high-refractory superalloy more than halved the number of solidification-related grain defects formed. These findings suggest that elemental interactions between Cr, Mo, W, and Re need to be considered when optimizing alloys for high-temperature creep properties.

Simulation of dendritic growth in the platform region of single crystal superalloy turbine blades

A cellular automaton model of the solid-liquid interface, combined with a finite difference computation of solute diffusion has been developed to simulate single crystal solidification in molds with step changes in geometry. Simulations were carried out for columnar dendrites passing from the narrow airfoil region of a blade into the platform region, which has an increased cross-sectional area. Different shapes of isotherms moving at a constant velocity were considered in the simulations. The change in mold geometry leads to a significant increase in the undercooling in front of the dendrite tips as they spread around the mold corner. The model was applied to geometries investigated by prior authors, correctly predicting the formation of a to boundary observed experimentally.

Solidification of high-refractory ruthenium-containing superalloys

The effect of alloy chemistry on single crystal solidification has been investigated in a series of model high refractory Ni-base superalloys with variations in ruthenium, rhenium and aluminum. Over the range of composition investigated, the initial phase to form during solidification was either the γ phase (FCC Ni-solid solution) or the δ phase (HCP Re-rich phase). In a quaternary Ni-Al-Ta-Re alloy containing 1.7 at.% (5.6 wt.%) Re, δ-Re nucleated at a temperature well above the liquidus temperature of pure Ni and grew unconstrained into six-fold Re-rich dendrites. These dendrites served as potent nucleation sites for γ grains as temperature decreased during directional solidification. Ruthenium additions in the range of 2.5∽9.0 at.% (4.1∽14.1 wt.%) lowered the temperature at which the δ nucleated and eventually suppressed the formation of this phase during solidification. Ru additions also increased the liquidus temperatures of the multicomponent superalloys. The implications for the design of Ru-containing superalloys are discussed.

Directional and single-crystal solidification of Ni-base superalloys: Part I. The role of curved isotherms on grain selection

The development of crystallographic texture during directional solidification has been quantitatively analyzed in columnar castings of the Ni-base superalloys, CMSX4 and CM186LC, produced with a range of cooling rates and liquidus front curvatures. It is proposed that the more diffuse crystallographic texture developed in CMSX4 relative to CM186LC results from a combination of the differing local orientation stability condition and the alloys’ solidification characteristics. The implications of these additional factors on the evolution of the axial grain texture, the grain orientations produced in singlecrystal processing, and the stability of spurious grains in processing CMSX4 are discussed. An experimental method is presented to quantitatively analyze the grain selection process in the case of curved liquidus isotherms by retaining the stereology of the primary 〈001〉 dendrite growth direction and the local thermal gradient vector. This can account for the stability of spuriously nucleated edge grains in a single-crystal matrix.

Directional and single-crystal solidification of Ni-base superalloys: Part II. Coincidence site lattice character of grain boundaries

The development of grain boundary misorientations with an evolving axial texture during directional solidification has been examined using the electron backscattered diffraction (EBSD) technique on the Ni-base superalloys, CMSX4 and CM186LC. A preferred grain boundary misorientation distribution (GBMD) for a sharp 〈001〉 axial texture in CM186LC was associated with a clustering of misorientation axes (MAx) in the proximity of 〈001〉. This is accompanied by an enhanced distribution of coincidence site lattice (CSL) boundaries. The increased distribution of low angle boundaries, Σ1 and Σ5, can be attributed to the existence of a preferred MAx and accommodation by secondary intrinsic grain boundary dislocations. The more diffuse 〈001〉 axial texture in CMSX4 is associated with a significant proportion of MAx deviating from 〈001〉 and a dramatic reduction in the proportion of CSL boundaries.

Single Crystal Solidification of Undercooled Single-phase Alloys

The correlation between dendritic microstructure and melt undercooling is investigated to present a new technique for rapid single crystal growing, or high undercooling directional solidification (HUDS). In a certain range of undercooling for stable dendrite growth in a negative temperature gradient, this new technique is employed to prepare single crystal Ni 50 Cu 50 bars of approximately 10 mm in diameter and 65 mm in length. Optical metallography and X-ray diffraction experiments indicate that the resulting single crystals in the directionally solidified bars are composed of dendrites approximately parallel to each other and growing mainly in the (100) directions. The formation process and growth velocity of single crystals in an undercooled liquid are analyzed according to the obtained results and calculated by a current dendrite growth theory, respectively. A comparison of the HUDS technique with the as-proposed autonomous directional solidification (ADS ) process is made also in the present paper.

The breakdown of single-crystal solidification in high refractory nickel-base alloys

The breakdown of single-crystal solidification has been studied over a wide range of solidification conditions in ten superalloys with large variations in Re, Ta, and W content. Over the range of experimental conditions investigated, grain defect formation was sensitive to local thermaland solutal conditions. For a fixed alloy composition and withdrawal rate, the transition from single-crystal to equiaxed solidification did not occur abruptly. Instead, as thermal gradients were decreased in a series of experiments, isolated, highly misoriented columnar grains with the same composition as that of the base alloy developed in the presence of positive (stabilizing) thermal gradients with increasing frequency until the advance of the single-crystal front was completely blocked. The onset of columnar grain formation occurred when the primary dendrite arm spacing exceeded a critical value, corresponding to a morphological transition in the dendritic array. The onset of “freckling” was observed at the same primary dendrite arm spacing where misoriented columnar grains began to appear. In experiments with varying levels of refractory alloy content, there was also a strong correlation between the onset of grain formation and freckle formation. These observations strongly suggest that in high refractory content superalloys, the breakdown of single-crystal solidification and the formation of misoriented grains as well as freckle-type defects are sensitively dependent on thermosolutal convection processes.

Thermal Mechanical Fatigue Behavior of Advanced Overlay Coatings

Abstract Environmental protection and cost effectiveness lead to the demand to increase the efficiency of energy conversion. In the past decade gas turbines have become an important factor in efficient power generation. Gas turbine inlet temperatures are being increased continuously to decrease the specific fuel consumption. The development of new base materials and sophisticated processes like single crystal solidification allows higher metal temperatures. This causes higher oxidative stress to the MCrAlY overlay coatings. As shown in an earlier paper (I), an improvement of the high temperature properties is achievable by the addition of Rhenium. In this paper we report on properl ies of MCrAlY coatings containing 8 to 12% Al and 10% Rhenium by weight. The coatings were applied on Inco 738 LC by LPPS (Low Pressure Plasma Spraying). Data for static oxidation and cyclic oxidation data at 950°C, I000°C up to 10,000 hours are presented. However, the main aim of this report is to discuss the thermal-mechanica...