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INTRODUCTION
The term "superalloy" was first used shortly after World War II to
As a supplement to The Minerals, describe a group of alloys developed for use in turbosuperchargers and
Metals & Materials Society's site aircraft turbine engines that required high performance at elevated
dedicated to the 9th International temperatures. The range of applications for which superalloys are used
Symposium on Superalloys, this
page was developed by Randy
has expanded to many other areas and now includes aircraft and land-
Bowman of NASA Lewis Research based gas turbines, rocket engines, chemical, and petroleum plants. They
Center. are particularly well suited for these demanding applications because of
their ability to retain most of their strength even after long exposure
times above 650C (1,200F). Their versatility stems from the fact that
they combine this high strength with good low-temperature ductility and excellent surface stability.
Superalloys are based on Group VIIIB elements and usually consist of various combinations of Fe, Ni,
Co, and Cr, as well as lesser amounts of W, Mo, Ta, Nb, Ti, and Al. The three major classes of
superalloys are nickel-, iron-, and cobalt-based alloys.
NICKEL-BASED SUPERALLOYS
Nickel-based alloys can be either solid solution or precipitation strengthened. Solid solutioned
strengthened alloys, such as Hastelloy X, are used in applications requiring only modest strength. In the
most demanding applications, such as hot sections of gas turbine engines, a precipitation strengthened
alloy is required. Most nickel-based alloys contain 10-20% Cr, up to 8% Al and Ti, 5-10% Co, and
small amounts of B, Zr, and C. Other common additions are Mo, W, Ta, Hf, and Nb (often still referred
to as "columbium" although the name "niobium" was adopted by the International Union of Pure and
Applied Chemistry in 1950 after more than 100 years of controversy). In broad terms, the elemental
additions in Ni-base superalloys can be categorized as being i) formers (elements that tend to partition
to the matrix, ii) ' formers (elements that partition to the ' precipitate, iii) carbide formers, and iv)
elements that segregate to the grain boundaries. Elements which are considered formers are Group V,
VI, and VII elements such as Co, Cr, Mo,W, Fe. The atomic diameters of these alloys are only 3-13%
different than Ni (the primary matrix element). ' formers come from group III, IV, and V elements and
include Al, Ti, Nb, Ta, Hf. The atomic diameters of these elements differ from Ni by 6-18%. The main
carbide formers are Cr, Mo, W, Nb, Ta, Ti. The primary grain boundary elements are B, C, and Zr. Their
atomic diameters are 21-27% different than Ni.
Gamma Prime ( '): The primary strengthening phase in nickel-based superalloys is Ni3(Al,Ti),
and is called gamma prime ( '). It is a coherently precipitating phase (i.e., the crystal planes of the
precipitate are in registry with the gamma matrix) with an ordered L12 (fcc) crystal structure. The
close match in matrix/precipitate lattice parameter (~0-1%) combined with the chemical
compatability allows the ' to precipitate homogeneously throughout the matrix and have long-
time stability. Interestingly, the flow stress of the ' increases with increasing temperature up to
about 650oC (1200oF). In addition, ' is quite ductile and thus imparts strength to the matrix
without lowering the fracture toughness of the alloy. Aluminum and titanium are the major
constituents and are added in amounts and mutual proportions to precipitate a high volume
fraction in the matrix. In some modern alloys the volume fraction of the ' precipitate is around
70%. There are many factors that contribute to the hardening imparted by the ' and include ' fault
energy, ' strength, coherency strains, volume fraction of ', and ' particle size.
Carbides: Carbon, added at levels of 0.05-0.2%, combines with reactive and refractory elements
such as titanium, tantalum, and hafnium to form carbides (e.g., TiC, TaC, or HfC). During heat
treatment and service, these begin to decompose and form lower carbides such as M23C6 and
M6C, which tend to form on the grain boundaries. These common carbides all have an fcc crystal
structure. Results vary on whether carbides are detrimental or advantageous to superalloy
properties. The general opinion is that in superalloys with grain boundaries, carbides are
beneficial by increasing rupture strength at high tempeature.
Topologically Close-Packed Phases: These are generally undesirable, brittle phases that can
form during heat treatment or service. The cell structure of these phases have close-packed atoms
in layers separated by relatively large interatomic distances. The layers of close packed atoms are
displaced from one another by sandwiched larger atoms, developing a characteristic "topology."
These compounds have been characterized as possessing a topologically close-packed (TCP)
structure. Conversely, Ni3Al (gamma prime) is close-packed in all directions and is called
geometrically close-packed (GCP).
TCPs ( , , Laves, etc.) usually form as plates (which appear as needles on a single-plane
microstructure.) The plate-like structure negatively affects mechanical properties (ductility and
creep-rupture.) Sigma appears to be the most deleterious while strength retention has been
observed in some alloys containing mu and Laves. TCPs are potentially damaging for two
reasons: they tie up and ' strengthening elements in a non-useful form, thus reducing creep
strength, and they can act as crack initiators because of their brittle nature.
APPLICATIONS
Nickel-based superalloys are used in load-bearing structures
to the highest homologous temperature of any common alloy
system (Tm = 0.9, or 90% of their melting point). Among the RELATED LINKS
most demanding applications for a structural material are
those in the hot sections of turbine engines. The preeminence Superalloy-Related Companies
of superalloys is reflected in the fact that they currently
comprise over 50% of the weight of advanced aircraft Axel Johnson Metals
coupled with the fact that the thermodynamic efficiency of Carpenter Technology Corporation
fact, during the past 30 years turbine airfoil temperature Howmet Corp.
Two major factors which have made this increase possible are Ladish
PCC Airfoils
1. Advanced processing techniques, which improved alloy Special Metals
cleanliness (thus improving reliability) and/or enabled Teledyne Allvac
the production of tailored microstructures such as Utica Corporation
directionally solidified or single-crystal material. Wyman-Gordon
2. The low modulus associated with the <100> directions enhances thermal mechanical fatigue
resistance in areas of constrained thermal expansionparticularly turbine vanes. In general, the
lack of transverse grain boundaries coupled with the lower modulus can result in 3-5 times
improvement in rupture life.
SC casting were developed during the 1970s and were a spin-off from the technological advances made
in the DS casting processes. SC casting are produced in a similar fashion to DS by selecting a single
grain, via a grain selector. During solidification, this single grain grows to encompass the entire part.
Single crystals obtain their outstanding strength through the elimination of grain boundaries that are
present in both equiaxed and directionally solidified materials. In addition, the elimination of grain
boundary strengtheners such as C, B, Si, and Zr raises the single crystal's melting point. By increasing
the alloy's melting point, the homogenization heat-treat temperature can be increased without fear of
incipient melting, thus allowing for more complete solutioning of the ' and thereby increasing alloy
strength and maximum use temperature.
FURTHER READING
The first comprehensive book on superalloysand probably the best single source of information
related to superalloysis, appropriately, Superalloys, published in 1972 by John Wiley & Sons. Since
the book's original publication, it has become widely regarded as the standard reference in the field of
superalloys. The 1987 edition, Superalloys II, although based on the original version was thoroughly
updated to reflect the latest developments in the field.
Additional information can also be gleaned from the following conference sites:
The content of this site was developed by Randy Bowman (randy.bowman@lerc.nasa.gov); your feedback is welcome.