Abstract
Ongoing demand for advanced aero gas turbine engines with lower fuel burn and commensurate reduced CO2 emissions require single crystal (SX) superalloys capable of operating at higher gas and metal temperatures beyond the capability of 2nd generation, 3% rhenium (Re)-containing SX alloys, currently used extensively in commercial and military flight engines. These complex cooled turbine blades and vane castings must have an excellent balance of high temperature mechanical properties, producibility, oxidation/hot corrosion resistance, coating compatibility including TBC performance and phase stability.
The highest strength nickel-base SX superalloys currently in production (3rd generation CMSX-10K® and CMSX-10N® alloys) contain 6–7% Re. These highly alloyed, specialty alloys have some application drawbacks including some secondary reaction zone (SRZ) phase instability in the base alloy adjacent to the coatings, low temperature internal oxidation/hot corrosion attack requiring sophisticated dual role internal and external coatings and difficulty in production solution heat treatment. In addition, current 3rd generation SX alloys have relatively higher density which is a disadvantage in terms of weight and inertia in rotating part applications, and high cost due to the elevated Re content.
An improved, lower Re content (4.8%), 3rd generation SX superalloy, CMSX-4® Plus (SLS) has been developed with improved properties and performance over current 3rd generation SX alloys, while lacking the drawbacks. Coatings have been successfully developed which are compatible with the base alloy and suitable bond coats for TBC application. This paper presents the characterization of CMSX-4 Plus (SLS) alloy, including composition, mechanical and physical properties, oxidation properties and phase stability, along with production status.
Effect of Re and Ta on Hot Corrosion Resistance of Nickel-Base Single Crystal Superalloys