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Lei Jia, Shufeng Yang, Zhengxin Tang, Qicong Liu, Peng Zhao, Gen Li, and Jinglong Qu, Controlling hot tearing in superalloys used in turbine disks operating above 800°C, Int. J. Miner. Metall. Mater., (2026). https://doi.org/10.1007/s12613-025-3280-x
Lei Jia, Shufeng Yang, Zhengxin Tang, Qicong Liu, Peng Zhao, Gen Li, and Jinglong Qu, Controlling hot tearing in superalloys used in turbine disks operating above 800°C, Int. J. Miner. Metall. Mater., (2026). https://doi.org/10.1007/s12613-025-3280-x
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800°C以上涡轮盘用高合金化镍基合金热裂纹控制研究

摘要: 航空发动机涡轮盘用高γ′强化镍基变形合金合金化程度持续提升,但高Al、Ti、Nb添加会加剧元素显微偏析、拓宽合金凝固温度区间,铸锭凝固末期易产生热撕裂缺陷,大规格铸锭开裂报废问题尤为突出。现有研究多聚焦小尺寸试样热处理与γ′相析出行为,缺乏对ϕ350 mm大直径GH4151铸锭热裂纹机理及控裂工艺的系统性研究。本文以Al+Ti+Nb总质量分数10%、γ′相体积分数超50%的GH4151真空感应熔炼铸锭为研究对象,综合采用DSC热分析、EPMA元素面扫、EBSD晶界表征、TEM物相鉴定与Gleeble力学测试,结合Thermo-Calc Scheil热力学计算、ProCAST元胞自动机-有限元耦合仿真,系统研究合金凝固路径、枝晶间元素偏析行为、晶间低熔相析出规律,阐明热撕裂萌生与扩展机制,并评价不同合金凝固裂纹指数(SCI)、应变时效裂纹指数(SAC),探索铸型预热、均匀化退火对残余应力、显微组织及开裂敏感性的调控效果。结果表明,GH4151合金中Nb、Ti、Mo在枝晶间强烈正偏析,凝固末期依次析出MC碳化物、η相、(γ + γ′)共晶、Laves相与M2B硼化物,宽凝固区间导致枝晶间液相补缩受阻,在热应力与相变应力共同作用下于缩孔处萌生裂纹,并沿取向差大于15°高角度晶界扩展;不含B、Zr合金临界热撕裂凝固区间为230°C,应变时效裂纹临界指数为0.0008。1050°C低温退火可缓解枝晶显微偏析、降低残余应力;提高铸型预热温度能够显著削弱凝固热应力峰值。铸型预热协同退火处理可同步弱化凝固区间与残余应力,消除铸锭宏观裂纹,退火后合金硬度由HV 401降至HV 358,抗拉强度由1075 MPa提升至1126 MPa,伸长率由3.22%提高至4.49%。本研究明确了高γ′镍基合金铸锭热裂纹形成的核心诱因,建立了兼顾凝固与固态相变的开裂评价体系,为大尺寸难变形高温合金无裂纹铸锭制备提供理论支撑与工艺方案。

 

Controlling hot tearing in superalloys used in turbine disks operating above 800°C

Abstract: To meet the requirements of high-performance aero-engines, the alloying degrees and γ′ phase mass fractions of newly wrought superalloys used in the aero-engines are maintained at high values, leading to elevated hot tearing susceptibility of the alloy. The hot cracking behavior of a large-diameter (ϕ350 mm) GH4151 superalloy with an Al + Ti + Nb content exceeding 10wt% and the γ′ phase content exceeding 50% was investigated via experiments and simulations. The solidification cracking and strain-age cracking (SAC) indices of different deformed superalloys were also evaluated. The results showed that the crack type of the GH4151 alloy was hot tearing. The cracks propagated intergranularly along high-angle grain boundaries. The hot tearing was due to excessive Mo, Nb, and Ti segregation in dendrites, creating a wide solidification range, and the successive formation of metastable carbide (MC), η, (γ + γ′) eutectic, Laves, and M2B phases during the last stage of solidification, hindering liquid phase replenishment and forming pore defects. The pores produced cracks under the influence of thermal and phase-transformation stresses. B and Zr in an alloy can significantly reduce its solidification range. The critical solidification range for hot cracking in B and Zr-free superalloys was 230°C, while their strain-age crack criterion was 0.0008. The residual stress and microstructure of the alloys could be significantly improved through mold preheating and annealing, finally leading to a crack-free ingot.

 

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