Nickel-Based Superalloy Composition for Creep-Resistant Aero-Engine Parts
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Solution Overview
Problem
Existing nickel-based superalloys do not meet the high-temperature and high-stress requirements of advanced aviation engines, leading to deformation, cracking, and failure due to dislocation movement.
Innovation Solution
A nickel-based superalloy composition with specific mass percentages of Co, Cr, Ta, Al, Ti, W, Mo, Nb, Hf, C, B, and Zr, synergistically strengthened by Nb, W, Ti, and Ta to generate Suzuki atmospheres at microtwinning and superlattice stacking faults, pinning dislocations and improving creep resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If existing nickel-based superalloys are used, then manufacturing and processing are feasible, but operating temperature cannot meet the requirements of advanced aviation engines (above 780°C)
Solution Approach 1:
The patent changes the chemical composition parameters of the nickel-based superalloy by precisely controlling the content ranges of key elements (Co: 17-22%, Cr: 9-13%, Ta: 2.95-3.95%, Al: 2.5-3.5%, Ti: 2.5-3.5%, W: 2.1-3.5%, Mo: 2.1-3.5%, Nb: 1.65-1.95%, Hf: 0.2-0.7%). This compositional optimization enhances the alloy's high-temperature strength and creep resistance, enabling operation above 780°C while maintaining reliability.
Solution Approach 2:
The patent creates a composite microstructure consisting of γ matrix and γ′ precipitates, where the γ′ phase (Ni3Al, Ni3Ti, Ni3Ta, Ni3W, Ni3Mo, Ni3Nb) acts as reinforcement. This dual-phase composite structure provides both ductility from the matrix and strength from the precipitates, allowing the alloy to withstand high temperatures and stresses without deformation or cracking.
2Power
If temperature before turbine is increased to improve engine performance, then engine thrust increases, but material deformation and failure occur due to dislocation movement
Solution Approach 1:
The patent optimizes alloy composition parameters to enhance dislocation resistance. Specifically, the controlled addition of strengthening elements (Ta, W, Mo, Nb) and γ′-forming elements (Al, Ti) creates a microstructure that effectively impedes dislocation motion, allowing the material to sustain higher stresses and temperatures required for increased engine thrust.
Solution Approach 2:
The γ-γ′ composite microstructure provides dual functionality: the γ matrix maintains ductility and toughness, while the γ′ precipitates act as obstacles to dislocation movement. This composite structure enables the alloy to withstand the high stresses generated at elevated turbine temperatures without undergoing plastic deformation or failure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The operating temperature of the superalloy is elevated to 780-830°C, meeting the demands of advanced aviation engines by enhancing creep resistance through element-specific Suzuki atmospheres.
Implementation Method 1
utilize Nb, W, Ti, and Ta to synergistically strengthen the γ′ phase, thereby generating element-specific Suzuki atmosphere at microtwinning and superlattice stacking faults, so as to lock the dislocations to improve creep resistance
Implementation Method 2
preparing the bar stock by vacuum induction melting
Implementation Method 3
processing the bar stock by vacuum induction gas atomization to obtain an alloy powder
Implementation Method 4
preparing a billet by treating the alloy powder by hot isostatic pressing
Data Source
AI summary
The present disclosure relates to the technical field of nickel-based superalloys, and in particular to a nickel-based superalloy and preparation method therefor, and a structural component. The alloy includes the following components in mass percentage: Co 17%-22%, Cr 9%-13%, Ta 2.95%-3.95%, Al 2.5%-3.5%, Ti 2.5%-3.5%, W 2.1%-3.5%, Mo 2.1%-3.5%, Nb 1.65%-1.95%, Hf 0.2%-0.7%, C 0.03%-0.08%, B 0.01%-0.06%, Zr 0.03%-0.07% and Ni. The nickel-based superalloys of the present disclosure, in the creep process at 780° C., produces specific Suzuki atmosphere in certain positions, and locks dislocations to improve creep resistance, such that the operating temperature can be raised to more than 780° C., which meets the requirements on the materials for the advanced aero-engines.