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EP2019150A1 - Procédé de contrôle et d'affinage de taille de grain final dans des superalliages à base de nickel traité thermiquement - Google Patents

Procédé de contrôle et d'affinage de taille de grain final dans des superalliages à base de nickel traité thermiquement Download PDF

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Publication number
EP2019150A1
EP2019150A1 EP08158579A EP08158579A EP2019150A1 EP 2019150 A1 EP2019150 A1 EP 2019150A1 EP 08158579 A EP08158579 A EP 08158579A EP 08158579 A EP08158579 A EP 08158579A EP 2019150 A1 EP2019150 A1 EP 2019150A1
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Prior art keywords
grain size
strain rate
astm
superalloy
gamma prime
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EP08158579A
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German (de)
English (en)
Inventor
Eric Scott Huron
Joseph Aloysius Heaney
David Alan Utah
Michael James Weimer
Kenneth Rees Bain
David Paul Mourer
Jon Raymond Groh
Edward Lee Raymond
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General Electric Co
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General Electric Co
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/10—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
    • C22C19/056—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 10% but less than 20%
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
    • C22C19/057—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being less 10%

Definitions

  • the present invention generally relates to methods for processing nickel-base superalloys. More particularly, this invention relates to a method of forging an article from a nickel-base superalloy, in which increased local strain rates in combination with increased carbon content promote a more controlled grain growth during supersolvus heat treatment, such that the article is characterized by a microstructure with a finer uniform grain size.
  • Gamma prime ( ⁇ ') precipitation-strengthened nickel-base superalloys contain chromium, tungsten, molybdenum, rhenium and/or cobalt as principal elements that combine with nickel to form the gamma ( ⁇ ) matrix, and contain aluminum, titanium, tantalum, niobium, and/or vanadium as principal elements that combine with nickel to form the desirable gamma prime precipitate strengthening phase, principally Ni 3 (Al,Ti).
  • Gamma prime precipitation-strengthened nickel-base superalloys are widely used for disks and other critical gas turbine engine components forged from billets produced by powder metallurgy (P/M), conventional cast and wrought processing, and spraycast or nucleated casting forming techniques.
  • Gamma prime nickel-base superalloys formed by powder metallurgy are particularly capable of providing a good balance of creep, tensile, and fatigue crack growth properties to meet the performance requirements of certain gas turbine engine components such as turbine disks.
  • a powder of the desired superalloy undergoes consolidation, such as by hot isostatic pressing (HIP) and/or extrusion consolidation.
  • the resulting billet is then isothermally forged at temperatures slightly below the gamma prime solvus temperature of the alloy to approach superplastic forming conditions, which allows the filling of the die cavity through the accumulation of high geometric strains without the accumulation of significant metallurgical strains.
  • These processing steps are designed to retain the fine grain size originally within the billet (for example, ASTM 10 to 13 or finer), achieve high plasticity to fill near-net-shape forging dies, avoid fracture during forging, and maintain relatively low forging and die stresses.
  • Forged gas turbine engine components often contain grains with sizes of about ASTM 9 and coarser, such as ASTM 2 to 9, though a much tighter range is typically preferred, such as grain sizes within a limited range of 2 to 3 ASTM units. Such a limited range can be considered uniform, which as used herein refers to grain size and growth characterized by the substantial absence of nonuniform critical grain growth.
  • critical grain growth refers to localized excessive grain growth in an alloy that results in the formation of grains outside typical uniform grain size distributions whose size sufficiently exceeds the average grain size in the alloy (such as regions as coarse as ASTM 00 in a field of ASTM 6-10) to negatively affect the low cycle fatigue (LCF) properties of an article formed from the alloy, manifested by early preferential crack nucleation in the CGG regions.
  • Critical grain growth can also have a negative impact on other mechanical properties, such as tensile strength. Critical grain growth occurs during supersolvus heat treatment following hot forging operations in which a wide range of local strains and strain rates are introduced into the material.
  • critical grain growth is believed to be driven by excessive stored energy within the worked article, and may involve individual grains, multiple individual grains within a small region, or large areas of adjacent grains.
  • the grain diameters of the effected grains are often substantially coarser than the desired grain size.
  • Disks and other critical gas turbine engine components forged from billets produced by powder metallurgy and extrusion consolidation have appeared to exhibit a lesser propensity for critical grain growth than if forged from billets produced by conventional cast and wrought processing or spraycast forming techniques, but in any event are susceptible to critical grain growth during supersolvus heat treatment.
  • the maximum strain rate is composition, microstructure, and temperature dependent, and can be determined for a given superalloy by deforming test samples under various strain rate conditions, followed by a suitable supersolvus heat treatment.
  • the maximum (critical) strain rate is then defined as the strain rate that, if exceeded during deformation and working of a superalloy and accompanied by a sufficient amount of total strain, will result in critical grain growth after supersolvus heat treatment.
  • Another processing limitation identified by Krueger et al. as avoiding critical grain growth in a nickel-base superalloy having a gamma prime content of, for example, 30-46 volume percent and higher, is to ensure superplastic deformation of the billet during forging.
  • the billet is processed to have a fine grain microstructure that achieves a minimum strain rate sensitivity (m) of about 0.3 or greater for the superalloy within the forging temperature range.
  • Yoon et al. cites an upper limit strain rate of below about 0.032 per second (s -1 ) for a gamma prime nickel-base superalloy identified as Alloy D and commercially known as René 88DT (R88DT; U.S. Patent No. 4,957,567 ).
  • René 88DT René 88DT
  • Yoon et al. also identifies a maximum strain rate of not more than about 0.032 s-1, particularly in reference to forging an alloy identified in Yoon et al. as Alloy A, which again is R88DT.
  • the present invention provides a method of forming components from gamma prime nickel-base superalloys.
  • the method entails formulating such a superalloy to have a sufficiently high carbon content and forging the superalloy at sufficiently high local strain rates so that, following a supersolvus heat treatment, the component is characterized by a fine and substantially uniform grain size distribution, preferably an average grain size finer than ASTM 7 and more preferably in an average range of about ASTM 8 to 10.
  • the present invention is further capable of avoiding critical grain growth that would produce individual grains or small regions of grains having grain sizes of more than five and preferably three ASTM units coarser than the average grain size in the component, or large regions that are uniform in grain size but with a grain size coarser than a desired grain size range of about two ASTM units.
  • the method includes formulating the superalloy to have a composition suitable for producing forged polycrystalline articles subjected to high temperatures and dynamic loads, a notable example of which is a turbine disk of a gas turbine engine.
  • a composition suitable for producing forged polycrystalline articles subjected to high temperatures and dynamic loads a notable example of which is a turbine disk of a gas turbine engine.
  • An exemplary example of such an alloy is the aforementioned gamma prime precipitation-strengthened nickel-base superalloy R88DT, though it is foreseeable that the teachings of this invention could be extended to other gamma prime nickel-base superalloys approximating the mechanical properties of R88DT critical to a turbine disk, such as low cycle fatigue life.
  • the superalloy employed in the method of this invention is formulated to have a carbon content of at least 0.045 weight percent, and preferably in excess of 0.060 weight percent, which is the conventional upper limit for carbon in R88DT.
  • a billet is formed of the superalloy and worked at a temperature below the gamma prime solvus temperature of the superalloy so as to form a worked article.
  • the billet is worked while maintaining strain rates as high as possible to control average grain size, but below an upper strain rate limit to avoid critical grain growth.
  • the billet is not required to be worked superplastically, i.e., can have a strain rate sensitivity (m) of less than 0.3 at the working (e.g., forging) temperature. In fact, it is preferred to work the billet non-superplastically to achieve the finest grain sizes.
  • the worked article is then heat treated at a temperature above the gamma prime solvus temperature of the superalloy for a duration sufficient to uniformly coarsen the grains of the worked article, after which the worked article is cooled at a rate sufficient to reprecipitate gamma prime within the worked article.
  • the cooled worked article has an average grain size of not coarser than ASTM 6 and preferably not coarser than 7 ASTM, for example, in a range of about ASTM 8 to 10.
  • a significant advantage of this invention is that, in addition to avoiding critical grain growth and avoiding the necessity to forge superplastically, the higher strain rate limit of the process window for working the billet has been shown to achieve significant control of the average grain size in the component and achieve a uniform grain size distribution within a desired narrower range that is significantly finer than previously possible. In this manner, mechanical properties of the component, including low cycle fatigue and tensile strength, can be improved.
  • Improvements in low cycle fatigue life are believed possible, with the further benefit of higher temperature properties achieved with powder metallurgy alloys such as R88DT.
  • Other benefits of the finer average grain size achieved with this invention include improved sonic inspection capability due to lower sonic noise, and improved yield behavior in service due to improved yield strength with finer grain size.
  • the present invention is particularly directed to components formed by forging gamma prime precipitation-strengthened nickel-base superalloys.
  • a particular example is high pressure turbine disks of gas turbine engines, which are typically formed by isothermally forging a fine-grained billet at temperatures at or near the recrystallization temperature of the alloy but less than the gamma prime solvus temperature of the alloy, and under superplastic forming conditions to enable filling of the forging die cavity through the accumulation of high geometric strains without the accumulation of significant metallurgical strains.
  • a supersolvus heat treatment is performed, during which grain growth occurs. In the past, such a supersolvus heat treatment has typically yielded an acceptable but not wholly optimal average grain size range of about ASTM 2 to 9.
  • the present invention identifies processing parameters by which a finer average grain size and more desirable grain size distribution can be achieved in a gamma prime precipitation-strengthened nickel-base superalloy, in addition to avoidance of critical grain growth.
  • a finer and more controllable average grain size can be achieved by increasing the strain rate during forging, resulting in a strain rate window having an upper limit that is higher than conventionally believed possible without inducing critical grain growth.
  • the upper limit of the strain rate window corresponds to the maximum strain rate at which critical grain growth can be avoided.
  • higher strain rates and non-superplastic deformation can be employed without causing critical grain growth by modifying an alloy to have a relatively high carbon content.
  • a billet is typically formed by powder metallurgy (P/M), a cast and wrought processing, or a spraycast or nucleated casting type technique. Such processes are carried out to yield a billet with a fine grain size, typically about ASTM 10 or finer, to achieve low flow stresses during forging. As previously noted, the ability of a fine grain billet to deform superplastically is dependent on strain rate sensitivity (m).
  • prior art billets for high pressure turbine disks have been formed under conditions, including a specified temperature range, to produce the desired fine grain size and also maintain a minimum strain rate sensitivity (m) of about 0.3 or greater within the forging temperature range.
  • m minimum strain rate sensitivity
  • strain rates higher than previously thought possible can be employed to produce suitable forgings without the forging process being fully superplastic, i.e., at strain rate sensitivity values of less than about 0.3.
  • the billet can be formed by consolidating a superalloy powder, such as by hot isostatic pressing (HIP) or extrusion consolidation, the latter of which preferably uses a sufficiently low ram speed to prevent adiabatic heating and limited only by equipment tonnage limitations and excessive chilling.
  • HIP hot isostatic pressing
  • extrusion consolidation preferably yields a fully dense, fine-grain billet preferably having at least about 98% theoretical density.
  • a high temperature soak is typically performed in a manner that prevents excessive coarsening of the overall grain size that would excessively and undesirably increase flow stresses.
  • a suitable soak has been achieved by simply preheating and holding the billet at its forging temperature for up to about five hours, though longer holding periods are also envisioned.
  • the billet is then hot worked (e.g., forged) to form a component having a desired geometry, followed by a supersolvus (solution) heat treatment.
  • a supersolvus (solution) heat treatment As taught by Yoon et al., under certain conditions an extended subsolvus annealing process or a low heating rate to the supersolvus heat treatment temperature may be desired to dissipate stored strain energy within the article and equilibrate the temperature of the component. Dissipation of stored strain energy can serve to reduce nonuniform nucleation tendencies of the superalloy, such that the tendency for critical grain growth in the component is also reduced.
  • an extended subsolvus anneal step appears to be unnecessary. Instead, merely preheating the worked billet (forging) to within about 50°F to about 75°F (about 30°C to about 40°C) or so of the prior forging temperature is sufficient without any extended soak time.
  • the supersolvus heat treatment is then performed at a temperature above the gamma prime solvus temperature (but below the incipient melting temperature) of the superalloy, to recrystallize the worked grain structure and dissolve (solution) the gamma prime precipitates in the superalloy.
  • a suitable supersolvus temperature is typically about 30°F to 70°F (about 15°C to 40°C) above the gamma prime solvus temperature of an alloy, though any temperature above the solvus temperature (but below the incipient melting temperature) is generally acceptable.
  • the component is cooled at an appropriate rate to re-precipitate gamma prime within the gamma matrix or at grain boundaries, so as to achieve the particular mechanical properties desired.
  • An example of a suitable cooling step includes controlled air cooling or controlled air cooling for a brief period followed by quenching in oil or another suitable medium.
  • the component may also be aged using known techniques with a short stress relief cycle at a temperature above the aging temperature of the alloy if desirable to reduce residual stresses.
  • Regions of the component with grain sizes in excess of about two to three ASTM units coarser than the desired grain size range are undesirable in that the presence of such grains can significantly reduce the low cycle fatigue resistance of the component and have a negative impact on other mechanical properties of the component, such as tensile and fatigue strength.
  • a component having a grain size range of about ASTM 5 to 8 is preferably free of isolated grains and small regions of grains coarser than ASTM 3 (though widely scattered grains slightly coarser may be tolerable), and free of significant regions coarser than about ASTM 6.
  • excessively large grains caused by critical grain growth can be avoided during working of the billet by maintaining strain rates below a critical (maximum) strain rate for the superalloy in accordance with Krueger et al.
  • mechanical properties would be further promoted by improving the grain size distribution and achieving a finer average grain size, for example, in a range of about ASTM 7 to 9, more preferably about 8 to 10.
  • improved grain size distribution and finer average grain size can be achieved by increasing the minimum strain rate of the strain rate window.
  • the maximum strain rate can be increased to values previously associated with causing critical grain growth in a given superalloy, but without inducing critical grain growth, by increasing the carbon content of the superalloy above its conventional upper limit.
  • the effect of the increased carbon content is believed to be an increased pinning force that inhibits abnormal grain growth.
  • finely dispersed carbides restrict grain boundary motion during supersolvus heat treatment, such that the grains are not permitted to grow excessively and/or randomly to the extent that critical grain growth occurs. From the investigations reported below, in addition to a more rapid forging process and improved properties, other benefits appear to be the ability to perform the forging operation at relatively low temperatures and under non-superplastic conditions (m ⁇ 0.3).
  • the critical strain rate of a gamma prime nickel-base superalloy is composition, microstructure, and temperature dependent, and can be determined for a given superalloy by deforming test samples under various strain rate conditions, and then performing suitable supersolvus heat treatments.
  • the critical strain rate is then defined as the strain rate that, if exceeded during deformation and working of a superalloy and accompanied by a sufficient amount of total strain, will result in critical grain growth after supersolvus heat treatment.
  • strain rates below a minimum strain rate result in an average grain size that may be coarser than desired for optimal properties.
  • the precise value for the minimum strain rate parameter of this invention appears to vary depending on the composition and microstructure of the superalloy in question. Strain rates for regions within large components can be predicted analytically by performing experiments on small laboratory specimens, and then using modeling techniques to predict local deformation behavior within the components.
  • Figure 1 is a graph representing strain rate versus temperature and resulting average grain sizes observed with forged specimens of the conventional R88DT alloy ("Prior art forgings") and forged specimens of alloys based on the R88DT but whose compositions were modified to contain elevated carbon levels in accordance with this invention ("Fine grain forgings").
  • the conventional and modified R88DT alloys differ in their carbon contents, with specimens of the conventional R88DT alloy containing about 0.045 to 0.060 weight percent carbon and specimens of the modified R88DT alloys containing greater than 0.060 weight percent carbon, preferably at least 0.065% to about 0.085% carbon, and possibly higher.
  • the bars in Figure 1 represent a shift in acceptable ranges for strain rates and forging temperatures identified through investigations leading to the present invention.
  • the upper extent of each bar represents the upper strain rate limit at which critical grain growth can be avoided in the specimens represented by that bar. From Figure 1 , it can be appreciated that the modified R88DT specimens are able to be forged at much higher rates than the conventional R88DT specimens without critical grain growth (about 0.1 s -1 maximum versus about 0.010 s -1 maximum).
  • Figure 1 also represents that significantly finer grains were obtained with the modified R88DT specimens (about ASTM 7 to about ASTM 9) as compared to the conventional R88DT specimens (about ASTM 6 to about ASTM 8).
  • chromium as having a composition of, by weight, about 15.0-17.0% chromium, about 12.0-14.0% cobalt, about 3.5-4.5% molybdenum, about 3.5-4.5% tungsten, about 1.5-2.5% aluminum, about 3.2-4.2% titanium, about 0.5.0-1.0% niobium, about 0.010-0.060% carbon, about 0.010-0.060% zirconium, about 0.010-0.040% boron, about 0.0-0.3% hafnium, about 0.0-0.01 vanadium, and about 0.0-0.01 yttrium, the balance nickel and incidental impurities.
  • the gamma prime solvus temperature of R88DT is estimated to be about 1950-2150°F (about 1065-1180°C), typically 2025-2050°F (about 1105-1120°C), for about 40 volume percent gamma prime.
  • the actual chemistries of the specimens are summarized in the table below.
  • Figures 2 and 3 plot, respectively, average ASTM grain size (ASTM Standard E 112) and ALA grain size (ASTM Standard E 930) versus strain rates for both groups of RCC specimens. All specimens were forged at a temperature of about 1850°F, 1875°F, or 1900°F (about 1010°C, about 1025°C, or about 1040°C), and at a strain rate within a range of about 0.00032 to about 1 sec !1 . Nominal strain levels were about 0.7%. Forging temperatures were selected on the basis of prior investigations with similar RCC and DC specimens of the conventional R88DT alloy (the basis for the conventional R88DT data represented in Figure 1 ).
  • Figure 5 is a graph plotting average and ALA grain size versus forging temperature for the 0.070% C specimens.
  • Figure 5 suggests that a trend also exists for finer and more uniform average grain sizes with decreasing forging temperature in the 0.070% C specimens. This trend was also found for the 0.066% C specimens, evidencing a broad processing window for high carbon contents and the potential benefits of lower forging temperatures.
  • high pressure turbine disks were forged and analyzed to further assess the above-described findings regarding the ability to obtain finer average grain size by increasing strain rates during forging.
  • Three of the disks were formed from R88DT modified to have a carbon content of either about 0.066 or about 0.070 weight percent, and were produced by powder metallurgy, extrusion consolidation, forging, and supersolvus heat treatment at about 2080°F (about 1140°C).
  • forging processes can be designed using simulation models to produce die shapes and achieve a forging press operation that controls the local strain and strain rate history of regions of a forging within desired parameters.
  • the forge rates for the disks and previous specimens can be compared on the basis of a maximum strain rate.
  • the 0.066% C and 0.070% C disks evaluated in this investigation were forged using nominally isothermal processes designed to achieve maximum strain rates of about 0.032 sec -1 .
  • the forging steps for the 0.066% C and 0.070% C disks were controlled on a local limit basis so that all regions of the forgings were at or below the 0.032 sec -1 upper limit.
  • Figures 6 and 7 are normal probability plots of the average and ALA grain size, respectively, of the three forgings (Forgings #2, #3, and #4) produced to have one of the above-noted 0.066% C, and 0.070% C compositions. Twenty measurements were obtained for each forging arrayed uniformly about the forging cross section. The data for the 0.066% C and 0.070% C forgings are plotted along with data obtained from a fourth disk of the same geometry, but formed from a conventional R88DT composition including a conventional carbon content of about 0.052 weight percent, and processed to the conventional strain rate limit of less than 0.010 sec !1 (Forging #1). Even with the complexity of geometric factors in a contoured forging, the improved practice of the invention demonstrates a finer mean average grain size by about 2 ASTM grain size numbers and an improvement in the mean ALA grain size by about 1 ASTM grain size number.
  • maximum strain rates of about 0.032 sec !1 and above, which correspond to strain rate sensitivity values of less than 0.3, should be employed to achieve the refined grain size throughout such forgings.
  • a target maximum strain rate will be uniformly achieved in all areas of the forging, and variations in strain rate can be such that setting an absolute minimum strain rate in the forging is not practical.
  • maximum strain rates capable of avoiding critical grain growth while achieving a finer grain size and distribution in accordance with the invention will inherently fall over a range.
  • a maximum strain rate can be set as a target within a range of suitable maximum strain rates for a given forging, in which an upper limit for the range is necessary to avoid critical grain growth and a lower limit of the range is necessary to avoid or minimize low strain areas that may not achieve sufficiently high strain rate work to obtain the desired fine grain size and distribution sought by the invention.
  • the forging shape may be defined so that the high strain rate non-superplastically deformed regions are located in specific areas advantageous to the part operation and life.
  • Figure 8 is a bar graph evidencing the improved sonicability of the 0.066% C and 0.070% C forgings of Figures 6 and 7 as compared to the conventional 0.052% C forging of Figures 6 and 7 .
  • the data show a reduction of sonic noise levels of about 40%, indicating improved inspectability compared to the conventional current processing and chemistry.
  • Figures 9 and 10 are normal probability plots comparing the ultimate tensile strength and yield strength, respectively, of the 0.066% C and 0.070% C forgings of Figures 6 and 7 as compared to the conventional 0.052% C forging of Figures 6 and 7 .
  • Both measures of tensile capability show a significant improvement of the mean value of about 9 to about 10 ksi (about 62 to about 69 MPa), when using methods and compositions of this invention as compared to currently existing methods and compositions.
  • the method of this invention makes possible the production of components from R88DT and similar gamma prime nickel-base superalloys that consistently exhibit a finer average grain size. While the benefits of the invention were described in reference to the R88DT superalloy processed from powder metal starting materials, other materials could be used including spraycast materials, cast and wrought materials, etc. Furthermore, gamma prime nickel-base superalloys having compositions sufficiently approximating that of R88DT to have similar mechanical properties as R88DT, such as low cycle fatigue life, are also believed to benefit from the processing and composition modifications of the present invention. An example of such an alloy is believed to be René 104 ( U.S. Patent No.
  • 6,521,175 with a nominal composition of about 16.0-20.0 percent cobalt, about 8.5-12.5 percent chromium, about 1.5-3.5 percent tantalum, about 2.0-4.0 percent tungsten, about 1.9-3.9 percent molybdenum, about 0.04-0.06 percent zirconium, about 1.0-3.0 percent niobium, about 2.6-4.6 percent titanium, about 2.6-4.6 percent aluminum, about 0.02-0.04 percent carbon, about 0.02-0.04 percent boron, the balance nickel and incidental impurities.

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EP08158579A 2007-06-28 2008-06-19 Procédé de contrôle et d'affinage de taille de grain final dans des superalliages à base de nickel traité thermiquement Withdrawn EP2019150A1 (fr)

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