New vision of convection induced freckle formation theory in Nickel-based superalloys by electron microscopy

Freckles, one of the common defects in blades used in heavy duty gas turbines, hugely deteriorates blades mechanical properties and liability under service conditions. Thermal-solutal convection theory is a widely adopted formation mechanism but few solid experimental evidences were reported. Here for the first time we systematically studied the microstructure of 117 grains in freckle chains from four different Nickel-based superalloys of either single crystal or directionally solidified alloys. The relationship between the internal stress and the misorientation throughout the freckle chains is studied by means of state-of-the-art electron microscopy. All results give new experimental proof to the theory of thermal-solutal convection, which is further supported by the fact that borides at the boundary are randomly orientated to alloys. Our results enrich the methodology of freckle study, providing a new sight of the formation mechanism of casting defects.