PM superalloys - A troubled adolescent?
The history of powder metallurgy P/M superalloy technology is reviewed with a comment on the state of the art, and speculates on the technology's future potential growth and maturity.
Dreshfield, R. L.↗
Engineering topics
Gray, H. R.
Publications and source records attributed to Gray, H. R..
P/M superalloys: A troubled adolescent?
The history of powder metallurgy P/M superalloy technology is reviewed with a comment on the state of the art, and speculates on the technology's future potential growth and maturity.
Dreshfield, R. L.↗
Advanced aircraft engine materials trends
Recent activities of the Lewis Research Center are reviewed which are directed toward developing materials for rotating hot section components for aircraft gas turbines. Turbine blade materials activities are directed at increasing metal temperatures approximately 100 C compared to current directionally solidified alloys by use of oxide dispersion strengthening or tungsten alloy wire reinforcement of nickel or iron base superalloys. The application of thermal barrier coatings offers a promise of increasing gas temperatures an additional 100 C with current cooling technology. For turbine disk alloys, activities are directed toward reducing the cost of turbine disks by 50 percent through near net shape fabrication of prealloyed powders as well as towards improved performance. In addition, advanced alloy concepts and fabrication methods for dual alloy disks are being studied as having potential for improving the life of future high performance disks and reducing the amount of strategic materials required in these components.
Dreshfield, R. L.↗
The effect of microstructure on hydrogen embrittlement of the nickel-base superalloy, Udimet 700
Material from a single heat of cast and wrought Udimet 700 was processed and/or heat treated to produce five material conditions with identical chemical compositions but with distinct microstructural variations, and then evaluated for susceptibility to hydrogen embrittlement. Two prealloyed powder conditions exhibited significantly improved resistance to hydrogen embrittlement, as compared to wrought material. No degradation in notch or smooth tensile strengths occurred, and average ductilities of 25 percent reduction of area were determined for 2 hydrogen evaluation procedures. For the most severe hydrogenation procedure, ductility levels were reduced to 15 percent. These improvements were attributed to cleaner grain boundaries and decreases grain size.
Gray, H. R.↗
The effect of microstructure on hydrogen embrittlement of the nickel base superalloy, Udimet 700
Material from a single heat of cast and wrought Udimet 700 was processed and/or heat treated to produce five material conditions with identical chemical compositions but with distinct microstructural variations, and then evaluated for susceptibility to hydrogen embrittlement. Two prealloyed powder conditions exhibited significantly improved resistance to hydrogen embrittlement, as compared to wrought material. No degradation in notch or smooth tensile strengths occurred, and average ductilities of 25 percent reduction of area were determined for 2 hydrogen evaluation procedures. For the most severe hydrogenation procedure, ductility levels were reduced to 15 percent. These improvements were attributed to cleaner grain boundaries and decreased grain size.
Gray, H. R.↗
The promise of eutectics for aircraft turbines
Gas turbine blades and vanes for the 1980s call for new materials with higher operational temperature capabilities. The potential increase of from 40 to 110 C in operational temperature capabilities predicted for directionally solidified eutectics is a larger increment over currently available alloys than previously obtained in any new turbine blade alloy. The paper discusses the properties of gamma/gamma prime-delta and NiTaC-13 directionally solidified first-generation eutectics for use as gas turbine blade materials. A few of the more promising second-generation eutectics for blade applications (gamma/gamma prime-alpha, NiTaC 3-116A) and for vane applications (gamma-beta, COTAC 74) are also discussed. Attention is given to mechanical properties, such as transverse ductility and shear strength, that can be inherently critical in a directionally solidified eutectic. Further R&D requirements for properties, coatings, and lower cost processing technology are identified.
Gray, H. R.↗
The promise of eutectics for aircraft turbines
The current status of the first generation eutectics, gamma/gamma transition - delta and NiTaC-13, is described in detail. Several second generation systems, such as gamma/gamma transition - alpha and NiTaC 3-116A, gamma - beta, and COTAC 74 are also reviewed with particular emphasis on their critical physical and mechanical properties, future research directions, and potential applications. Results of recent cost-benefit analyses of eutectic turbine blades are discussed.
Gray, H. R.↗
Effect of thermal cycling in a Mach 0.3 burner rig on properties and structure of directionally solidified gamma/gamma prime-delta eutectic
An experimental study was carried out to evaluate the effect of cyclic thermal exposures on the mechanical properties of a gamma/gamma prime-delta eutectic alloy parallel to the growth direction. The alloy had a nominal composition by weight of Ni-20 Nb-6 Cr-2.5 Al and was directionally solidified at 3 cm/hr in a furnace with a thermal gradient of at least 200 C/cm. Bars of the alloy were exposed in a Mach 0.3 burner rig and cycled 300 times between 1100 and 425 C. Oxidation-erosion characteristics of the alloy were determined by weight loss measurements at 300-cycle intervals. After cyclic exposure, stress rupture and tensile tests were performed at both 760 and 1040 C. Microstructural changes from cyclic exposure were determined. Thermal cycling resulted in gamma prime coarsening and Widmanstaetten delta precipitation in the gamma phase. An unidentified precipitate, presumably gamma prime, was observed within the delta phase. These microstructural changes did not affect the mechanical properties of the eutectic. High oxidation-erosion weight loss rate was observed.
Gray, H. R.↗
Hydrogen environment embrittlement of turbine disk alloys
Astroloy and V-57, two candidate turbine disk alloys for the auxiliary power unit (APU) of the space shuttle propulsion and power system were tested for their resistance to embrittlement in hydrogen environments. Samples of both these nickel-base alloys were subjected to notch and smooth tensile testing and to creep testing in hydrogen. The high resistance exhibited by Astroloy forgings to embrittlement by hydrogen is attributed to the microstructure produced by forging and also to the special heat treatment schedule. V-57 turbine disks successfully completed short-time performance testing in the experimental APU. The use of the Astroloy, however, would permit increasing turbine inlet temperature and the rotational speed beyond those possible with V-57.
Gray, H. R.↗
Potential structural material problems in a hydrogen energy system
Potential structural material problems that may be encountered in the three components of a hydrogen energy system - production, transmission/storage, and utilization - have been identified. Hydrogen embrittlement, corrosion, oxidation, and erosion may occur during the production of hydrogen. Hydrogen embrittlement is of major concern during both transmission and utilization of hydrogen. Specific materials research and development programs necessary to support a hydrogen energy system are described. An awareness of probable shortages of strategic materials has been maintained in these suggested programs.
Gray, H. R.↗
Hydrogen environment embrittlement of astroloy and Udimet 700 (nickel-base) and V-57 (iron-base) superalloys
The sensitivity to hydrogen environment embrittlement of three superalloys was determined. Astroloy forgings were resistant to embrittlement during smooth tensile, notched tensile, and creep testing in 3.5-MN/sq m hydrogen over the range 23 to 760 C. The notched tensile strength of Udimet 700 bar stock in hydrogen at 23 C was only 50 percent of the baseline value in helium. Forgings of V-57 were not significantly embrittled by hydrogen during smooth tensile testing over the range 23 to 675 C; creep and rupture lives of V-57 were degraded by hydrogen. Postcreep tensile ductility of V-57 was reduced by 40 percent after creep exposure in hydrogen.
Gray, H. R.↗
Materials considerations
Materials problems are examined that may be encountered within a hydrogen energy system. Emphasis is placed on hydrogen embrittlement, corrosion, oxidation, and erosion. Other factors discussed include: degradation of mechanical properties of structural alloys, system reliability, and maintenance costs.
Gray, H. R.↗
Effect of thermal cycling in a Mach 0.3 burner rig on properties and structure of directionally solidified gamma/gamma prime - delta eutectic
Tensile and stress rupture properties at 1040 C of a thermally cycled gamma/gamma prime - delta eutectic were essentially equivalent to the as-grown properties. Tensile strength and rupture life at 760 C appeared to decrease slightly by thermal cycling. Thermal cycling resulted in gamma prime coarsening and Widmanstatten delta precipitation in the gamma phase. An unidentified precipitate, presumably gamma prime, was observed within the delta phase. The eutectic alloy exhibited a high rate of oxidation-erosion weight loss during thermal cycling in the Mach 0.3 burner rig.
Gray, H. R.↗
Potential structural material problems in a hydrogen energy system
Potential structural material problems that may be encountered in the three components of a hydrogen energy system - production, transmission/storage, and utilization - were identified. Hydrogen embrittlement, corrosion, oxidation, and erosion may occur during the production of hydrogen. Hydrogen embrittlement is of major concern during both transmission and utilization of hydrogen. Specific materials research and development programs necessary to support a hydrogen energy system are described.
Gray, H. R.↗
Tensile and creep properties of titanium-vanadium, titanium-molybdenum, and titanium-niobium alloys
Tensile and creep properties of experimental beta-titanium alloys were determined. Titanium-vanadium alloys had substantially greater tensile and creep strength than the titanium-niobium and titanium-molybdenum alloys tested. Specific tensile strengths of several titanium-vanadium-aluminum-silicon alloys were equivalent or superior to those of commercial titanium alloys to temperatures of 650 C. The Ti-50V-3Al-1Si alloy had the best balance of tensile strength, creep strength, and metallurgical stability. Its 500 C creep strength was far superior to that of a widely used commercial titanium alloy, Ti-6Al-4V, and almost equivalent to that of newly developed commercial titanium alloys.
Gray, H. R.↗
Embrittlement of nickel-, cobalt-, and iron-base superalloys by exposure to hydrogen
Five nickel-base alloys (Inconel 718, Udimet 700, Rene 41, Hastelloy X, and TD-NiCr), one cobalt-base alloy (L-605), and an iron-base alloy (A-286) were exposed in hydrogen at 0.1 MN/sq m (15 psi) at several temperatures in the range from 430 to 980 C for as long as 1000 hours. These alloys were embrittled to varying degrees by such exposures in hydrogen. Embrittlement was found to be: (1) sensitive to strain rate, (2) reversible, (3) caused by large concentrations of absorbed hydrogen, and (4) not associated with any detectable microstructural changes in the alloys. These observations are consistent with a mechanism of internal reversible hydrogen embrittlement.
Gray, H. R.↗
Turbine materials and life prediction
The recent developments and future potential of advanced materials for turbine components are described. The components discussed in detail are disks, blades, and vanes.
Gray, H. R.↗
Effect of exposure cycle on hot salt stress corrosion of a titanium alloy
The influence of exposure cycle on the hot-salt stress-corrosion cracking resistance of the Ti-8Al-1Mo-1V alloy was determined. Both temperature and stress were cycled simultaneously to simulate turbine-powered aircraft service cycles. Temperature and stress were also cycled independently to determine their individual effects. Substantial increases in crack threshold stresses were observed for cycles in which both temperature and stress or temperature alone were applied for 1 hour and removed for 3 hours. The crack threshold stresses for these cyclic exposures were twice those determined for continuous exposure for the same total time of 96 hours.
Gray, H. R.↗