Low-Density, Creep-Resistant Single-Crystal Superalloys

Several recently formulated nickel-base superalloys have been developed with excellent high-temperature creep resistance, at lower densities than those of currently used nickel-base superalloys. These alloys are the latest products of a continuing effort to develop alloys that have even greater strength-to-weight ratios, suitable for use in turbine blades of aircraft engines. Mass densities of turbine blades exert a significant effect on the overall weight of aircraft. For a given aircraft, a reduction in the density of turbine blades enables design reductions in the weight of other parts throughout the turbine rotor, including the disk, hub, and shaft, as well as supporting structures in the engine. The resulting total reduction in weight can be 8 to 10 times that of the reduction in weight of the turbine blades. The approach followed in formulating these alloys involved several strategies for identifying key alloying elements and the range of concentration of each element to study. To minimize the number of alloys needed to be cast, a design-of--experiments methodology was adopted. A statistics-based computer program that models the effects of varying compositions of four elements, including effects of two-way interactions between elements, was used to test all possible alloys within the design space. The starting points for the computational analysis were three alloy compositions mandated by engineering consensus. After likewise identification of key alloying elements to vary and the allowed ranges of concentrations, the computer program then selects a minimum number of alloys within the design space to allow determination of effects for all four elements and their interactions.