Skip to main content
SpringerLink
Log in

Developing Alloy Compositions for Future High Temperature Disk Rotors

  • Conference paper
  • First Online:
Superalloys 2020

Part of the book series: The Minerals, Metals & Materials Series ((MMMS))

Abstract

Two new alloy compositions for possible disk rotor applications have been examined. Both were intended to have higher \( \gamma ^{{\prime }} \) content than the existing alloy, RR1000, and be produced using powder metallurgy and isothermal forging to enable forgings to show a consistent coarse grain microstructure. Small pancake forgings of the new alloys and RR1000 were made and from these, blanks were cut, solution heat treated, cooled at measured rates and aged. Results of screening tests to understand the tensile, creep and dwell crack growth behavior, oxidation resistance and phase stability of these new alloys and coarse grain RR1000 are reported. The development alloys were similar in composition but exhibited different tensile and creep properties, phase stability and resistance to oxidation damage. Despite attempts to minimize variation in microstructure from heat treatment, differences in \( \gamma ^{{\prime }} \) size distribution were found to influence tensile and creep behavior. One of the new alloys (Alloy 2) showed improved yield and tensile strength compared to RR1000. Alloy 2 displayed similar initial creep strain behavior to RR1000 but superior resistance to subsequent creep damage, producing longer creep rupture lives. All of the alloys showed crack retardation at low stress intensity factor ranges (ΔK) from 3600 s dwell cycles at 700 °C in air. This occurred whilst crack growth was intergranular. Alloy 1 was found to precipitate C14 Laves phase from long term exposure at 800 °C. Like RR1000, σ phase was not detected in the new alloys after 750 h at 800 °C.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 349.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 449.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info
Hardcover Book
USD 449.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

References

  1. European Commission, (2001), European Aeronautics: A Vision for 2020.

    Google Scholar 

  2. European Commission, (2011), Flightpath 2050 Europe’s vision for aviation. https://doi.org/10.2777/50266.

  3. Reed RC, Mottura A, Crudden DJ, (2016), Alloys-by-design: towards optimization of compositions of nickel-based superalloys. In: Superalloys 2016, (Ed. by Hardy MC et al.), TMS, Warrendale, p 15–23.

    Google Scholar 

  4. Mitchell RJ, Lemsky JA, Ramanathan R, Li HY, Perkins KM and Connor LD, (2008), Process development & microstructure & mechanical property evaluation of a dual microstructure heat treated advanced nickel disc alloy. In: Superalloys 2008, (Ed. by Reed RC et al.), TMS, Warrendale, p 347–356.

    Google Scholar 

  5. https://www.icao.int/Meetings/EnvironmentalWorkshops/Documents/ICAO-TransportCanada-2006/Anderson_ops.pdf.

  6. Dreshfield RL, Gray HR, (1984), P/M Superalloys – a Troubled Adolescent, NASA Technical Memorandum, TM-83623, Lewis Research Center, Cleveland.

    Google Scholar 

  7. Anderson R, (1990), Powder Metallurgy at Pratt and Whitney, The International Journal of Powder Metallurgy, 26, (2):171–178.

    Google Scholar 

  8. Smythe S, (2008), Superalloy powders: an amazing history, Advanced Materials and Processes, November: 52–55. https://www.asminternational.org/documents/10192/1887146/amp16611p052.pdf/6664af73-fa87-4c2f-8b94-d420d5c438e3/AMP16611P052.

  9. Hardy MC, Zirbel B, Shen G, Shankar R, (2004), Developing damage tolerance and creep resistance in a high strength nickel alloy for disc applications. In: Superalloys 2004, (Ed. by Green KA et al.), TMS, Warrendale, p 83–90.

    Google Scholar 

  10. Reppich B, (1982), Some new aspects concerning particle hardening mechanisms in γ′ precipitating Ni-based alloys – I. theoretical concept, Acta Metall., 30:87–94.

    Google Scholar 

  11. Parthasarathy TA, Rao SI, Dimiduk DM, (2004), A fast spreadsheet model for the yield strength of superalloys. In: Superalloys 2004, (Ed. by Green KA et al.), TMS, Warrendale, p 887–896.

    Google Scholar 

  12. Kozar RW, Suzuki S, Milligan WW, Schira JJ, Savage MF, Pollock TM, (2009), Strengthening mechanisms in polycrystalline multimodal nickel-base superalloys, Met. Trans. A, 40, (7):1588–1603.

    Google Scholar 

  13. Crudden DJ, Mottura A, Warnken N, Raeisinia B, Reed RC, (2014), Modelling of the influence of alloy composition on flow stress of high-strength nickel-based superalloys, Acta Mater., 75:356–370.

    Google Scholar 

  14. Galindo-Nava EI, Connor LD, Rae CMF, (2015), On the prediction of the yield stress of unimodal and multimodal γ′ nickel-base superalloys, Acta Mater., 98:377–390.

    Google Scholar 

  15. Hardy M, Reed R, Crudden D, (2018), European Patent Specification EP 3 112 485 B1, 15 August 2018.

    Google Scholar 

  16. Hardy MC, Reed RC, Crudden D, (2019), United States Patent US 10,266,919 B2, 23 April 2019.

    Google Scholar 

  17. Hardy MC, Reed RC, Crudden D, (2019), United States Patent US 10,422,024 B2, 24 September 2019.

    Google Scholar 

  18. Saunders N, (1996), Phase diagram calculating for Ni-Based Superalloys. In: Superalloys 1996, (Ed. by Kissinger RD et al.), TMS, Warrendale, PA, USA, p 101–110.

    Google Scholar 

  19. Small CJ, Saunders N, (1999), The application of CALPHAD techniques in the development of a new gas-turbine disk alloy, MRS Bulletin, 24, (4): 22–26.

    Google Scholar 

  20. Saunders N, Fahrmann M, Small CJ, (2000), The application of CALPHAD calculations to Ni-Based Superalloys. In: Superalloys 2000, (Ed. by Pollock TM et al.), Warrendale, p 803–811.

    Google Scholar 

  21. Antonov S, Detrois M, Helmink RC, Tin S, (2015), Precipitate phase stability and compositional dependence on alloying additions in γ-γ′-δ-η Ni-based superalloys, Journal of Alloys and Compounds, 626:76–86.

    Google Scholar 

  22. Telesman J, Kantzos P, Gayda J, Bonacuse PJ, Prescenzi A, (2004), Microstructural variables controlling time-dependent crack growth in a P/M superalloy. In: Superalloys 2004, (Ed. by Green KA et al.), TMS, Warrendale, p 215–224.

    Google Scholar 

  23. Evans HE, (1988), Cavity formation and metallurgical changes induced by growth of oxide scale, Materials Science and Technology, 4, (12):1089–1098.

    Google Scholar 

  24. Sudbrack CK, Evans LJ, Garg A, Perea DE and Schreiber DK, (2016), Characterization of grain boundaries and associated minor phases in disk alloy ME3 exposed at 815 °C. In: Superalloys 2016, (Ed. by Hardy MC et al.), TMS, Warrendale, p 927–936.

    Google Scholar 

  25. Connolley T, Starink MJ, Reed PAS, (2000), Effect of oxidation on high temperature fatigue crack initiation and short crack growth in Inconel 718. In: Superalloys 2000, (Ed. by Pollock TM et al.), TMS, Warrendale, p 435–444.

    Google Scholar 

  26. Huron ES, Bain KR, Mourer DP, Gabb T, (2008), Development of high temperature capability P/M disk superalloys. In: Superalloys 2008, (Ed. by Reed RC et al.), TMS, Warrendale, p 181–189.

    Google Scholar 

  27. Christofidou KA, Hardy MC, Li HY, Argyrakis C, Kitaguchi H, Jones NG, Mignanelli PM, Wilson AS, Messé OMDM, Pickering EJ, Gilbert RJ, Rae CMF, Yu S, Evans A, Child D, Bowen P and Stone HJ, Met. Trans., 49A (9):3896–3907.

    Google Scholar 

  28. Tien JK, Jarrett RN, (1983), Effects of Cobalt in Nickel-Base Superalloys, NASA Contractor Report CR168308, NASA Lewis Research Center, Cleveland.

    Google Scholar 

  29. Luthra KL, (1982), Low temperature hot corrosion of cobalt-base alloys: part I. morphology of the reaction product, Met. Trans. A, 13, (10):1843–1852.

    Google Scholar 

  30. Lillerud KP, Kofstad P, (1984), Sulfate-Induced hot corrosion of nickel, Oxidation of Metals, 21, (5/6):233–270.

    Google Scholar 

  31. Reed RC, (2009), The Superalloys, Fundamentals and Applications, Chapter 2, Cambridge University Press, ISBN 9780511541285, https://doi.org/10.1017/CBO9780511541285.

  32. Randle V, (1997), Mechanism of twinning-induced grain boundary engineering in low stacking-fault energy materials, Acta Mater., 47, (15):4187–4196.

    Google Scholar 

  33. Christofidou KA, Jones NG, Pickering EJ, Flacau R, Hardy MC, Stone HJ, (2016), The microstructure and hardness of Ni-Co-Al-Ti-Cr quinary alloys, Journal of Alloys and Compounds, 688:542–552.

    Google Scholar 

  34. Morinaga M, Yukawa N, Adachi H, Ezakil H, (1984), New PHACOMP and its application to alloy design. In: Superalloys 1984, (Ed. by Gell M et al.), TMS, Warrendale, p 523–532.

    Google Scholar 

  35. Guédou J-Y, Augustins-Lecallier I, Nazé L, Caron P, Locq D, (2008), Development of a new Fatigue and creep resistant PM nickel-base superalloy for disk applications. In: Superalloys 2008, (Ed. by Reed RC et al.), TMS, Warrendale, p 21–30.

    Google Scholar 

  36. Cruchley C, Evans HE, Taylor MP, Hardy MC, Stekovic S, (2013), Chromia layer growth on a Ni-based superalloy: sub-parabolic kinetics and the role of titanium, Corrosion Science, 75:58–66.

    Google Scholar 

  37. Pedrazzini S, Rowlands BS, Turk A, Parr IMD, Hardy MC, Bagot PAJ, Moody MP, Galindo-Nava E, Stone HJ, (2019), Partitioning of Ti and kinetic growth predictions on the thermally grown chromia scale of a polycrystalline nickel-based superalloy, Met. Trans A., 50, (7):3024–3029.

    Google Scholar 

  38. Pedrazzini SD, Child DJ, West G, Doak SS, Hardy MC, Moody MP, Bagot PAJ, (2016), Oxidation behaviour of a next generation polycrystalline Mn containing Ni-based superalloy, Scripta Materialia, 113:51–54.

    Google Scholar 

  39. White CL, Schneibel JH, Padgett RA, (1983), High temperature embrittlement of Ni and Ni-Cr alloys by trace elements, Met. Trans. A, 14, (4):595–610.

    Google Scholar 

  40. Gayda J, Gabb TP, Miner RV, (1985), Fatigue Crack Propagation of Nickel-Base Superalloys at 650 °C, NASA Technical Memorandum 87150, NASA Lewis Research Center, Cleveland.

    Google Scholar 

  41. Garosshen TJ, Tillman TD, McCarthy GP, (1987), Effects of B, C, Zr on the structure and properties of a P/M nickel base superalloy, Met. Trans. A, 18, (1):69–77.

    Google Scholar 

  42. Jain SK, Ewing BA, Yin CA, (2000), The development of improved performance PM Udimet® 720 turbine disks. In: Superalloys 2000, (Ed. by Pollock TM et al.), TMS, Warrendale, p 785–794.

    Google Scholar 

  43. ASTM E963-95, Standard Practice for Electrolytic Extraction of Phases from Ni and Ni-Fe Base Superalloys Using a Hydrochloric-Methanol Electrolyte, ASTM International, West Conshohocken.

    Google Scholar 

  44. Shulz F, Li HY, Kitaguchi H, Child D, Williams S, Bowen P, (2018), Influence of tertiary gamma prime (γ′) size evolution on the dwell crack growth behaviour in CG RR1000, Met. Trans. A, 49, (9):3874–3884.

    Google Scholar 

  45. Cruchley S, Taylor MP, Evans HE, Hardy MC, Child DJ, (2014), Characterisation of subsurface oxidation damage in Ni based superalloy, RR1000, Materials Science and Technology, 30, (15):1884–1889.

    Google Scholar 

  46. Wilson AS, Christofidou KA, Evans A, Hardy MC, Stone HJ, (2019), Comparison of methods for quantification of topologically closed packed phases in Ni-based superalloys, Met. Trans. A, 50, (12):5925–5934.

    Google Scholar 

  47. Papadaki C, (2019), Optimising Creep Resistance of Next Generation Nickel-Based Superalloys via Tailoring of γ′ Precipitates Using Different Heat Treatments, Confirmation of Status Report, Trinity College, University of Oxford, Oxford.

    Google Scholar 

  48. Mitchell RJ, Preuss M, (2007), Inter-relationships between the composition, γ′ morphology, hardness, and γ-γ′ mismatch in advanced polycrystalline nickel-base superalloys during aging at 800 °C, Met. Trans. A, 38, (3):615–627.

    Google Scholar 

  49. Chen Y, Prasath Babu R, Slater TJA, Bai M, Mitchell R, Ciuca O, Preuss M, Haigh SJ, (2016), Acta Materialia, 110:295–305.

    Google Scholar 

  50. Groh JR, (1996), Effect of cooling rate from solution heat treatment on Waspaloy microstructure and properties. In: Superalloys 1996, (Ed. by Kissinger RD et al.), TMS, Warrendale, p 621–626.

    Google Scholar 

  51. Galindo-Nava EI, Rae CMF, (2016), Microstructure-senstive modelling of dislocation creep in polycrystalline FCC alloys: Orowan theory revisited, MSEA, 651:116–126.

    Google Scholar 

  52. Gabb TP, Gayda J, Telesman J, Garg A, (2008), The effects of heat treatment and microstructure variations on disk superalloy properties at high temperature. In: Superalloys 2008, (Ed. by Reed RC et al.), TMS, Warrendale, p 121–130.

    Google Scholar 

  53. Li HY, Sun JF, Hardy MC, Evans HE, Williams SJ, Doel TJA, Bowen P, (2015), Effects of microstructure on high temperature dwell fatigue crack growth in a coarse grain PM nickel based superalloy, Acta Mater., 90:355–369.

    Google Scholar 

  54. Telesman J, Gabb TP, Ghosn LS, (2016), Separating the influence of environment from stress relaxation effects on dwell fatigue crack growth in a nickel-base disk alloy. In: Superalloys 2016, (Ed. by Hardy MC et al.), TMS, Warrendale, p 551–560.

    Google Scholar 

  55. Evans HE, Li HY, Bowen P, (2013), A mechanism for stress-aided grain boundary oxidation ahead of cracks, Scripta Materialia, 69:79–182.

    Google Scholar 

  56. Sudbrack CK, Draper SL, Gorman TT, Telesman J, Gabb TP, Hull DR, (2012), Oxidation and the effects of high temperature exposures on notched fatigue life of an advanced powder metallurgy disk superalloy. In: Superalloys 2012, (Ed. by Huron ES et al.), TMS, Warrendale, PA, p 863–872.

    Google Scholar 

  57. Miner RV Jr. (1977), Effects of silicon on the oxidation, hot-corrosion and mechanical behavior on two cast nickel-base superalloys, Met. Trans. A, 8, (12):1949–1954.

    Google Scholar 

  58. Reed R, Crudden D, Raeisinia B, Hardy M, (2016), European Patent Specification EP2 894 234 B1, 19 October 2016.

    Google Scholar 

Download references

Acknowledgements

This work was supported by Rolls-Royce plc and the Rolls-Royce/EPSRC Strategic Partnership under EP/H022309/1, EP/H500375/1 and EP/M005607/1. Dr Hardy would like to thank Rolls-Royce colleague Dr Han Tai for his support and encouragement in this work, Professor Roger Reed and Dr David Crudden from the University of Oxford for fruitful discussions and Mr Joe Muha, formerly of ATI Specialty Materials, Robinson, for his assistance in making the powder compacts.

Author information

Authors and Affiliations

  1. Rolls-Royce Plc, Derby, UK

    M. C. Hardy, C. Argyrakis, R. C. Buckingham, P. M. Mignanelli & D. J. Child

  2. Department of Materials Science and Metallurgy, University of Cambridge, Cambridge, UK

    A. S. Wilson, K. A. Christofidou, N. G. Jones, C. M. F. Rae & H. J. Stone

  3. School of Materials and Metallurgy, University of Birmingham, Birmingham, UK

    H. S. Kitaguchi, S. Yu, C. Jackson, S. C. H. Llewelyn, H. Y. Li & P. Bowen

  4. Allegheny Technologies Incorporated (ATI) Forged Products Cudahy, Cudahy, WI, USA

    K. Severs

  5. Bundesanstalt Für Materialforschung Und –Prüfung (BAM), Berlin, Germany

    A. Evans

  6. Department of Materials, University of Manchester, Manchester, UK

    E. J. Pickering

  7. Department of Engineering Science, University of Oxford, Oxford, UK

    C. Papadaki

Authors
  1. M. C. Hardy
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. C. Argyrakis
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. H. S. Kitaguchi
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. A. S. Wilson
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. R. C. Buckingham
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. K. Severs
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. S. Yu
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. C. Jackson
    View author publications

    You can also search for this author in PubMed Google Scholar

  9. E. J. Pickering
    View author publications

    You can also search for this author in PubMed Google Scholar

  10. S. C. H. Llewelyn
    View author publications

    You can also search for this author in PubMed Google Scholar

  11. C. Papadaki
    View author publications

    You can also search for this author in PubMed Google Scholar

  12. K. A. Christofidou
    View author publications

    You can also search for this author in PubMed Google Scholar

  13. P. M. Mignanelli
    View author publications

    You can also search for this author in PubMed Google Scholar

  14. A. Evans
    View author publications

    You can also search for this author in PubMed Google Scholar

  15. D. J. Child
    View author publications

    You can also search for this author in PubMed Google Scholar

  16. H. Y. Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  17. N. G. Jones
    View author publications

    You can also search for this author in PubMed Google Scholar

  18. C. M. F. Rae
    View author publications

    You can also search for this author in PubMed Google Scholar

  19. P. Bowen
    View author publications

    You can also search for this author in PubMed Google Scholar

  20. H. J. Stone
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to M. C. Hardy .

Editor information

Editors and Affiliations

  1. Illinois Institute of Technology, Chicago, IL, USA

    Sammy Tin

  2. Rolls-Royce, Derby, UK

    Mark Hardy

  3. PCC Structurals, Portland, OR, USA

    Justin Clews

  4. ISAE-ENSMA, Chasseneuil-du-Poitou, France

    Jonathan Cormier

  5. University of Science and Technology, Beijing, China

    Qiang Feng

  6. Collins Aerospace, Windsor Locks, CT, USA

    John Marcin

  7. ATI Specialty Materials, Monroe, NC, USA

    Chris O'Brien

  8. GE Global Research, Niskayuna, NY, USA

    Akane Suzuki

Rights and permissions

Reprints and permissions

Copyright information

© 2020 Rolls-Royce plc

About this paper

Check for updates. Verify currency and authenticity via CrossMark

Cite this paper

Hardy, M.C. et al. (2020). Developing Alloy Compositions for Future High Temperature Disk Rotors. In: Tin, S., et al. Superalloys 2020. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-030-51834-9_2

Download citation

Publish with us

Policies and ethics

Search

Navigation