<i style="">In-Situ</i> Monitoring of Phase Transition and Microstructure Evolution in Ni-Based Superalloys by Electrical Resistivity:Direct Comparison With Differential Scanning Calorimetry and Application to Case Studies

In this study, resistivity measurements are made during continuous heating and cooling on four different Ni-based superalloys of different grain structures and with different phases (i.e., γ′ and carbide). The results are directly compared with differential scanning calorimetry (DSC) profiles to identify the material’s resistivity response. The resistivity measurements have been performed using an electro-thermal mechanical testing (ETMT) system having a capability of heating and cooling a sample at a rate of up to 100 K/s by Joule heating, which is not possible with standard heating methods used in previous in-situ microstructure analysis approaches. By comparing different precipitate variations and thermal histories, γ′ volume fraction and precipitate number density are found to be the most important factors determining the resistivity of the materials. In-situ resistivity measurement was applied to several case studies to show that it can provide microstructural information in complex high temperature experiments.<br/

<i style="">In-Situ</i> Monitoring of Phase Transition and Microstructure Evolution in Ni-Based Superalloys by Electrical Resistivity:Direct Comparison With Differential Scanning Calorimetry and Application to Case Studies

In this study, resistivity measurements are made during continuous heating and cooling on four different Ni-based superalloys of different grain structures and with different phases (i.e., γ′ and carbide). The results are directly compared with differential scanning calorimetry (DSC) profiles to identify the material’s resistivity response. The resistivity measurements have been performed using an electro-thermal mechanical testing (ETMT) system having a capability of heating and cooling a sample at a rate of up to 100 K/s by Joule heating, which is not possible with standard heating methods used in previous in-situ microstructure analysis approaches. By comparing different precipitate variations and thermal histories, γ′ volume fraction and precipitate number density are found to be the most important factors determining the resistivity of the materials. In-situ resistivity measurement was applied to several case studies to show that it can provide microstructural information in complex high temperature experiments.<br/

Overheating of Waspaloy:Effect of cooling rate on flow stress behavior

During service of a gas turbine engine, components may suffer instant overheating which is a concern to safe operations. Effect of short overheating on the tensile properties of a Ni-based superalloy Waspaloy has been studied due to its significant importance for practical applications. The results have shown that a combination of near supersolvus overheating at 1000 °C with very rapid cooling at a rate of 50 K/s is most detrimental case to the tensile properties of the material. This is attributed to the absence of γ' and carbide re-precipitation and growth during cooling period. Microstructure change during overheating and cooling has been deduced using in-situ resistivity measurements. This work provides evidence that multilateral measurements including resistivity can shed light on the failure controlling parameters

Overheating of Waspaloy:Effect of cooling rate on flow stress behavior

During service of a gas turbine engine, components may suffer instant overheating which is a concern to safe operations. Effect of short overheating on the tensile properties of a Ni-based superalloy Waspaloy has been studied due to its significant importance for practical applications. The results have shown that a combination of near supersolvus overheating at 1000 °C with very rapid cooling at a rate of 50 K/s is most detrimental case to the tensile properties of the material. This is attributed to the absence of γ' and carbide re-precipitation and growth during cooling period. Microstructure change during overheating and cooling has been deduced using in-situ resistivity measurements. This work provides evidence that multilateral measurements including resistivity can shed light on the failure controlling parameters

A Comparative Study of High Temperature Tensile and Creep Testing Between Standard and Miniature Specimens:Applicability and Limits

This study concerns the quasi-static and time-dependent mechanical behavior obtained via the miniaturized electro-thermal mechanical testing (ETMT) approach for single crystal (SX) and conventional cast Mar-M-247 superalloy. The experimental outcome was benchmarked against standardized testing procedures. It is found that tensile yielding behavior can be captured accurately by the ETMT approach up to 1100 ºC, provided the appropriate type of thermocouple (T/C) is chosen. Furthermore, creep rupture behavior is underestimated by the miniaturized set-up. High repeatability of the rupture time was obtained for the SX case, whereas a significant scatter was observed for the conventional cast case. The discrepancies are assessed in detail; discussion centers around analytical and practical considerations, such as temperature uncertainty due to parasitic voltage and the choice of T/C, microstructural change as a result of the Joule heating, representative gauge volume, and strain rate non-linearity. Consequently, the applicability and limits of the miniaturized approach are examined critically, and improvements were suggested where appropriate

Indentation Plastometry for Study of Anisotropy and Inhomogeneity in Maraging Steel Produced by Laser Powder Bed Fusion

This work concerns the use of profilometry-based indentation plastometry (PIP) to obtain mechanical property information for maraging steel samples produced via an additive manufacturing route (laser powder bed fusion). Bars are produced in both “horizontal” (all material close to the build plate) and “vertical” (progressively increasing distance from the build plate) configurations. Samples are mechanically tested in both as-built and age-hardened conditions. Stress–strain curves from uniaxial testing (tensile and compressive) are compared with those from PIP testing. Tensile test data suggest significant anisotropy, with the horizontal direction harder than the vertical direction. However, systematic compressive tests, allowing curves to be obtained for both build and transverse directions in various locations, indicate that there is no anisotropy anywhere in these materials. This is consistent with electron backscattered diffraction results, indicating that there is no significant texture in these materials. It is also consistent with the outcomes of PIP testing, which can detect anisotropy with high sensitivity. Furthermore, both PIP testing and compression testing results indicate that the changing growth conditions at different distances from the build plate can lead to strength variations. It seems likely that what has previously been interpreted as anisotropy in the tensile response is in fact due to inhomogeneity of this type

Alloy Design for Additive Manufacturing:Early-Stage Oxidation of Nickel-Based Superalloys

This body of work aims to inform alloy design for additive manufacturing by investigating the early-stage oxidation behavior of Ni-based superalloys processed by laser-powder bed fusion. The oxidation of 14 Ni-based superalloys—some novel and some heritage—at 1000 °C for 24 hours is studied through thermo-gravimetric analysis. The mass gain, oxide layer thickness, oxide scale composition, and depletion γ' zone size are measured. The influence of the alloy composition on these variables is assessed in order to elucidate how increasingly processable and oxidation resistant alloys can be developed. The alloy compositions with Al content greater than 9 at. pct form continuous Al2O3 scales at 1000 °C and display markedly lower parabolic rate constants, mass gain, oxide layer thickness, and γ' depletion zone size. The alloys of lesser Al content have reduced oxidation resistance and formed oxide scales of predominantly Cr2O3. Alloys with Ti content of 2.7 at. pct and greater formed Ti-rich oxide phases in their oxide scales as well as TiN subscale. A trade-off between alloy processability and oxidation resistance is identified, dictated by the deleterious effect of Al content on the ductility dip and the benefit of Al for oxidation resistance. A property space along the pareto front is highlighted which is ideal for having oxidation resistance and processability

On the size-dependent fatigue behaviour of laser powder bed fusion Ti-6Al-4V

A sample size effect which influences the fatigue behaviour of laser powder bed fusion Ti-6Al-4V is identified and quantified. Two cylindrical samples are considered: ∅ 1.3 mm and ∅ 2.0 mm. The larger specimen demonstrates better fatigue resistance particularly in the high-cycle regime, with the differing surface roughness contributing to this effect. It is also confirmed that processing-induced porosity can compromise the fatigue performance even when the initiation sites are surface defects. The larger contribution of porosity to the fatigue fracture process of the larger specimen results in a higher scatter in the fatigue life. Differences in microstructure do not seem to contribute strongly to the variation in fatigue properties of the two specimens, but we present some evidence that the coarser microstructure of the larger specimen promotes a stronger tolerance to defects and induces more tortuous crack paths which hinders fatigue crack growth

On the Influence of Alloy Composition on the Additive Manufacturability of Ni-Based Superalloys

The susceptibility of nickel-based superalloys to processing-induced crack formation during laser powder-bed additive manufacturing is studied. Twelve different alloys—some of existing (heritage) type but also other newly-designed ones—are considered. A strong inter-dependence of alloy composition and processability is demonstrated. Stereological procedures are developed to enable the two dominant defect types found—solidification cracks and solid-state ductility dip cracks—to be distinguished and quantified. Differential scanning calorimetry, creep stress relaxation tests at 1000 °C and measurements of tensile ductility at 800 °C are used to interpret the effects of alloy composition. A model for solid-state cracking is proposed, based on an incapacity to relax the thermal stress arising from constrained differential thermal contraction; its development is supported by experimental measurements using a constrained bar cooling test. A modified solidification cracking criterion is proposed based upon solidification range but including also a contribution from the stress relaxation effect. This work provides fundamental insights into the role of composition on the additive manufacturability of these materials