Precipitation of Topologically Closed Packed Phases during the Heat-Treatment of Rhenium Containing Single Crystal Ni-Based Superalloys

Continual development of nickel-based superalloys for single-crystal turbine applications has pushed their operating temperatures higher and higher, most notably through the addition of rhenium. However, this has left them susceptible to the precipitation of topologically closed packed phases (TCPs), which are widely considered detrimental. Whilst these have long been reported as an end-of-life phenomenon in in-service components, they have more recently been observed during the manufacture of turbine blades. Several rhenium-containing alloys (CMSX-4, CMSX-10K, and CMSX-10N) were cast into single-crystal test bars and studied at different times along their solution heat-treatment process to discern if, when, and where these TCPs precipitated. It was seen that all alloys were susceptible to TCPs at some point along the process, with the higher rhenium-containing alloy CMSX-10N being the most prone. They occurred at the earliest stages of the solution process; this was attributed to aluminium diffusion from the segregated interdendritic regions into the dendrite core, causing the concentration of rhenium into the gamma-matrixes until sufficient potential was achieved for TCP precipitation. As the samples became more homogeneous, fewer TCPs were observed; however, in the case of CMSX-10N, this took longer than the typical 24-h solution time used in industry, leading to components entering service with TCPs still present.