Superalloy

The highly aHoyed austenitic stainless steels are proprietary modifications of the standard AISI 316 stainless steel. These have higher creep—mpture strengths than the standard steels, yet retain the good corrosion resistance and forming characteristics of the standard austenitic stainless steels. Nickel-Base Superalloys. 

Table 4. Chemical Composition of Wrought and Powder Nickel-Base Superalloys, wt %...

Table 6. Compositions and Densities of Superalloy Single Crystals...

Table 8. Materials Properties of Oxide Dispersion Strengthened Superalloys ...

Appllca.tlons. The principal appHcations of nickel-base superalloys are in gas turbines, where they are utilized as blades, disks, and sheet metal parts. Abcraft gas turbines utilized in both commercial and military service depend upon superalloys for parts exposed to peak metal temperatures in excess of 1000°C. Typical gas turbine engines produced in the United States in 1990 utilized nickel and cobalt-base superalloys for 46% of total engine weight (41). However, programs for future aerospace propulsion systems emphasize the need for lightweight materials having greater heat resistance. For such apphcations, intermetallics matrix composites and ceramic composites are expected to be needed. 

Fig. 10. 1000 h stress—rupture curves of wrought cobalt-base (Haynes 188 and L-605) and wrought iron-base superalloys (49). To convert MPa to psi,... 

G. H. Gessiager, Powder Metallurgy of Superalloys, Butterworths, London, 1984, p. 282. 

Metal injection mol ding (MIM) holds great promise for producing complex shapes in large quantities. Spray forming, a single-step gas atomization and deposition process, produces near-net shape products. In this process droplets of molten metal are coUected and soHdifted onto a substrate. Potential appHcations include tool steel end mills, superalloy tubes, and aerospace turbine disks (6,7). 

Using rapid solidification technology molten metal is quench cast at a cooling rate up to 10 °C/s as a continuous ribbon. This ribbon is subsequently pulverized to an amorphous powder. RST powders include aluminum alloys, nickel-based superalloys, and nanoscale powders. RST conditions can also exist in powder atomization. 

E. E. Brown, R. C. Boettner, and D. L. Ruckle, Superalloys—Processing Proceedings of the Second International Conference TMS, Warrendale, Ohio, 1972,... 

An alloy of molybdenum containing 1.2% hafnium with carbon at the level of 0.08—0.10% has a slight advantage over TZM. This alloy has been produced in small quantities for special extmsion dies and ejector pins in the isothermal forging of superalloys. 

Because of constitutional complexity, the exact chemistries of nickel-base superalloys must be controlled carehiUy in order to avoid the precipitation of deleterious topologically close-packed (TCP) phases and extraneous carbides after long-term high temperature exposure. Heat-treatment schedules and thermomechanical treatments in the case of wrought alloys also are important to provide optimum strength and performance. 

E. F. Bradley, Superalloys, A Technical Guide, ASM International, Materials Park, Ohio, 1988. 

Niobium is important as an alloy addition in steels (see Steel). This use consumes over 90% of the niobium produced. Niobium is also vital as an alloying element in superalloys for aircraft turbine engines. Other uses, mainly in aerospace appHcations, take advantage of its heat resistance when alloyed singly or with groups of elements such as titanium, tirconium, hafnium, or tungsten. Niobium alloyed with titanium or with tin is also important in the superconductor industry (see High temperature alloys Refractories). 

Table 10. Hard Metals and Superalloys for High Temperature Bearings ...

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