Super Alloy Parts in Aviation

The first successful airliner aircraft (in World War II, the German and British Army) were manufactured with relatively modest, material-limited motors. As they progressed, jet engines continued to be material-oriented. Nevertheless, it shows a spectacular series of tests carried out since 1942, which allowed the continuous rise of temperature and operating stress. Developments are both process and alloy-oriented, and are often a combination of both. As a result, the 1942's Whittle engine's net thrust of 800 lbs rose to 65,000 pounds 80 in a little over 40 years.

Initially, cobalt-based alloys appeared as the leader of binder manufacturing, while ferrous alloys provided lower temperatures, such as disks. More or less sophisticated traditional practice forged alloys, such as S-816, is waved into coarse grained, precision molded cobalt-based alloy parts. Then the industry learned how to regulate the particle size and structure, designers learn how to use less stress than desired, and the operating temperature rose to 815 ° C. Precise casting of super alloy components, it is now and still plays a decisive role in the super alloy world.

There were parallel developments in Ni-base systems, valuable, flexible, and now dominant, reinforced alloys. Here he took over the process development of vacuum metallurgy, which allows the production of strong "high alloy" compositions by controlling the impurities. Then, even higher alloy content, which results in greater strength and temperature potential, has been developed through the development of hopeful technologies, of which vacuum arc drawing is the most prominent. These developments required the parallel efforts of research and development teams to present and evaluate the role of the composition and structure of the alloy to exploit the benefits of previously unattainable purity levels and to develop advanced techniques to further modify structures and chemicals to solve specific problems. Ultimately, this has led to exciting developments of solidified and single-crystal blades, the latter having only recently reached the engine. During this period, the concerns of metallurgists, designers and manufacturers have always been that nickel-based and cobalt-based alloys need to be replaced with alloys with higher melting alloys with refractory metals. It is hardly surprising to realize that increased alloys generally produce lower melting alloys; There were alloys in higher and higher fractions of their melting temperatures!

At first, great efforts were made with molybdenum and columbium alloys (niobium). These were unsuccessful at the then planned operating temperatures and life expectancy, but there are still promises that are above 1100 ° C (2000 ° F) if suitable coatings are present. They have achieved high strength levels and have developed some promising coatings, but life expectancy has not been realized. Later, chromium-base alloys seemed natural, but due to fragility problems, it failed.

We should also mention the early experiments with cermets and the development of a range of ceramics from 1950, all of which have resulted in interesting solid structures but are still not acceptable applications in the super alloy competition. The austenitic super alloys remained dominant.

By processing fast solidification, more and more complex alloys are being developed and studied, now with the aim of further controlling the segregation of contaminants and the structure of the desired phases. In addition, the production of fine grain size and structures in the field of powder manufacturing is superplasticity easy to access and utilize. Molded aluminum alloys, such as IN-100 and Mar-M 509, are very strong at low and moderate temperatures and can easily be formed into complex shapes, including close net shapes. In the 1960s, who would have ever predicted that the IN-100 alloy alloy would be unmatched and would have been able to produce 650-700 ° C (1200-1300 ° F) disk applications? Superplastic structures can have a high impact on superalloy technology.

ODS Super-alloy Parts

Finally, we begin to apply the ODS (Oxide Dispersion-Enhanced) Alloys Significantly, again with the blend of processes and alloying techniques developed over the years. Mechanical alloying and now RS (fast solidification, fine, fully alloyed powders) allow the use of ODS nickel base and cobalt base alloys at temperatures above 1100 ° C (2000 ° F).

Application at 1100 ° C (2000 ° F) or higher for alloys melting below 1400 ° C (2550 ° F)? Above 80% of the absolute melting temperature? Yes, this time has come. Melting point can even reach larger fractions with metal-grade composites.

To sum up, coupled with the highly effective interaction of the alloys and the structure of the alloy processes, coupled with the superior scientific knowledge of the structures, properties and stability, super alloys represent a technical position that has never dreamed of its early suggestions!

Alternative alloys and materials are purchased but have not yet been published. These new materials are being studied to replace or replace super-alloy components.

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