Application of single crystal superalloys for earth-to-orbit propulsion systems

Single crystal superalloys were first identified as potentially useful engineering materials for aircraft gas turbine engines in the mid-1960s. Although they were not introduced into service as turbine blades in commercial aircraft engines until the early 1980's, they have subsequently accumulated tens of millions of flight hours in revenue producing service. The Space Shuttle main engine (SSME) and potential advanced earth-to-orbit propulsion systems impose severe conditions on turbopump turbine blades which for some potential failure modes are more severe than in aircraft gas turbines. Research activities which are directed at evaluating the potential for single crystal superalloys for application as turbopump turbine blades in the SSME and advanced rocket engines are discussed. The mechanical properties of these alloys are summarized and the effects of hydrogen are noted. The use of high gradient directional solidification and hot isostatic pressing to improve fatigue properties is also addressed.