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Understanding the oxidation of Ni-based single crystal (SX) superalloys is significantly important because oxidation can damage the microstructure and eventually lead to failure of the alloy. Using advanced scanning/transmission electron microscopy, oxidation effects on the microstructure of a SX superalloy during heat treatment and simulated service (stress/temperature coupling) conditions are systematically investigated in order to reveal oxide microstructures and oxidation mechanisms. Heat treatment in argon results in less weight loss, thinner γ′-free layer and fewer internal oxidation than that treated in air. But the oxide layer structures and influence depths of oxidation in both atmospheres are similar. External tensile stress not only accelerates the oxidation of alloy but also affects the oxide microstructures. Moreover, stress effects on the oxidation microstructure depend on temperature. At 750 °C, Ni–Co oxides are formed on the alloy surface, followed by the inner layer of Ni–Co–Mo–Re–W oxides at the location of original γ phase under stress free condition. As the stress increases, an oxide layer mainly containing Al, Cr, Nb, Mo and Re elements is formed between the above two oxide layers. When temperature increases to 1050 °C, as applied tensile stress increases, the thickness of oxide layer increases but the structure of oxide layer is not obviously changed. [ABSTRACT FROM AUTHOR]

The alloying effects on the microstructure, especially precipitation of harmful phases and solvus temperature of L1 2 -structured γʹ phase, etc., are essential for alloy design and development of precipitation strengthened Co-based superalloys. Based on the newly reported Co30Ni9Al5Mo10Cr2Ta0.03B alloy, alloying elements Mo, Cr, Al, Ta and Ni are systematically changed and alloys are fabricated to investigate their microstructures in two heat treatment statuses, namely homogenization and aging, respectively. Results show that Mo and Cr are γ forming elements and have limited effect on γʹ solvus temperature, but high concentration of Mo and Cr facilitates the formation of harmful μ phase. Al, Ta, and Ni are all γʹ stabilizers and can effectively increase γʹ solvus temperature, but roles of Al, Ta and Ni are different. Increasing Al and Ta would result in other harmful phases, such as the μ phase in the 6Ta and 4Ta alloys, and μ + B2 phases in the 13Al and 11.5Al alloys. However, Ni addition significantly increases solvus temperature and area fraction of γʹ phase without occurrence of harmful phases. The current findings might provide guidelines for design and development of precipitation strengthened Co-based alloys. [Display omitted] • The alloying effects of Mo, Cr, Ta, Al & Ni are systematically investigated. • Mo & Cr are γ formers, which facilitate the formation of μ phase. • Ta is a strong γˊ former, but excessive Ta facilitates the formation of TCP phase. • Al is necessary for γˊ phase, but excessive Al results in B2 & TCP phases. • Ni stabilizes γˊ phase without forming the harmful phases in Co-based alloys. [ABSTRACT FROM AUTHOR]

This work investigates the effect of Ru on the solution heat treatment window of the Ni-based single crystal superalloy. The addition of the Ru influences the solidification microstructure and widens the window. The solidification process is established to occur in the sequence of γ (dendrite) → γ + γ' grid eutectic (inter-dendrite) → γ + γ' lamella eutectic (inter-dendrite) → γ' (inter-dendrite). This is followed by the γ → γ + γ' decomposition of the γ dendrite into the common channel-cuboid structure upon cooling. The solvus of γ' and the solidus of the alloy define the window. In alloys containing inter-dendrite eutectic, the window is in principle zero. In this case, only the dynamic window created by homogenization diffusion may allow heat treatment. Adding Ru decreases the elements' partition ratios between the dendrite core and dendrite edge regions. It also promotes the enrichment of Re at the γ/γ' phase interfaces, which helps to refine the γ + γ' channel-cuboid structure and reduce the differences in both the size and volume fraction of the γ' phase between dendrite core and dendrite edge. Ru is found to inhibit the formation of (Ta, X)C carbide. These help widen the solution treatment temperature window of the Ni-based single crystal alloy. [Display omitted] • The solidification of the Ni-based single crystal superalloy is established. • The addition of the Ru can widen the solution heat treatment window. • The metallurgical principle behind the window of solution heat treatment is explained. • The effect of Ru on the window and the microstructure in cross-scale is clarified. [ABSTRACT FROM AUTHOR]

The precipitation and growth morphology of topologically close-packed (TCP) phases in a Re-containing Ni-based single crystal superalloy during thermal exposure were studied. The alloy was found to develop acicular-shaped coherent μ phase particles along <110> γ directions of the matrix after exposure at 950 °C. P phase precipitates were found to form with increased time and at higher temperatures, and in different morphologies, including acicular shaped particles along <112> γ and <110> γ directions, and plate-like particles in {110} γ planes of the matrix. The different P phase precipitates were found to have different lattice constants and different lattice correspondences with the matrix. The μ phase precipitate was also found to have different lattice correspondences with those reported in the literature. The multiplicity of lattice correspondences for the same TCP phase is attributed to the different lattice parameters, which render the precipitates to have different coherency relationships with the matrix. [ABSTRACT FROM AUTHOR]

The oxidation behavior of a fourth-generation nickel-based single crystal superalloy with different heat treatments were studied at 1100 °C in air. The specimens were divided into three groups, one as-cast group, and two heat-treated groups: solution treated and fully heat treated. The elemental distribution is mainly affected by the solution temperature, the higher the solution temperature, the more uniform the distribution of elements. Heat treatment can effectively reduce the difference in oxidation behavior between dendritic region and interdendritic region. However, due to the inability to form a continuous Al 2 O 3 layer, the oxidation resistance of heat-treated specimens degrades. • The elements distribution will affect the oxidation behavior of superalloys. • The Al content of the region will affect the morphology of the internal Al 2 O 3 layer. • Heat treatment can reduce the oxidation difference between dendritic region and interdendritic region. • After heat treatment, the alloy is more prone to large-scale oxide spalling. [ABSTRACT FROM AUTHOR]