SUPERALLOYS718, 625, 706AND DERIVATIVES

SUPERALLOYS 718, 625, 706 AND DERIVATIVES 2005

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SUPERALLOYS718, 625, 706AND DERIVATIVES

Proceedings of the Sixth International Symposium on Superalloys 718, 625, 706 and Derivatives sponsored by the Structural Materials Division (SMD) of TMS (The Minerals, Metals & Materials Society). Held October 2-5, 2005.

Edited by E.A. Loria

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v

Table of Contents

Preface....................................................................................................................................................... xi

Dedication .................................................................................................................................................xiii

Organizing Committee .............................................................................................................................. xv

Allvac® 718plus™, Superalloy for the Next Forty Years ............................................................................ 1

R.L. Kennedy

Extending the Size of Alloy 718 Rotating Components ............................................................................ 15

R. Schwant, S. Thamboo, L. Yang, and M. Morra

Alloy 718 Large Ingots Studies ................................................................................................................. 25

C. Malara, and J. Radavich

Metals Affordability Initiative: Application of Allvac Alloy 718Plus® for Aircraft Engine Static

Structural Components ............................................................................................................................. 35

E.A. Ott, J. Groh, and H. Sizek

Advancing Alloy 718 Vacuum Arc Remelting Technology Through Developing Model-Based

Controls..................................................................................................................................................... 47

R.L. Williamson, J.J. Beaman, F.J. Zanner, and J.J. DeBarbadillo

Alloy 718 Forging Development for Large Land-Based Gas Turbines ..................................................... 57

J.F. Uginet, and J.J. Jackson

Clean Metal Nucleated Casting of Superalloys ........................................................................................ 69

W.T. Carter, J.J. Jackson, R.M.F. Jones, and R.S. Minisandram

Modification of Alloy 706 for High Temperature Steam Turbine Rotor Application .................................. 77

S. Imano, H. Doi, K. Kajikawa, and T. Takahashi

Optimizing the Forging of Critical Aircraft Parts by the Use of Finite Element Coupled

Microstructure Modeling............................................................................................................................ 87

M. Stockinger, and J. Tockner

Probabilistic Life of DA718 for Aircraft Engine Disks ................................................................................ 97

S. Deyber, F. Alexandre, J. Vaissaud, and A. Pineau

Processing of Rolling Technologies for Alloy 718................................................................................... 111

M. Walter, and A. Tatschl

Mechanical Properties of Counter-Gravity Cast IN718........................................................................... 123

S. Shendye, B. King, and P. McQuay

The Role of Niobium in Wrought Precipitation-Hardened Nickel-Base Alloys........................................ 135

G.D. Smith, and S.J. Patel

vi

Structure and Property Comparison of Allvac® 718Plus™ Alloy and Waspaloy Forgings .................... 155

I. Dempster, W.-D. Cao, R. Kennedy, B. Bond, J. Aurrecoechea,

and M. Lipschutz

Solidification and Solid State Phase Transformation of Allvac® 718plus™ Alloy .................................. 165

W.-D. Cao

Structure Stability Study on a Newly Developed Nickel-Base Superalloy – Allvac®

718plus™................................................................................................................................................ 179

X. Xie, G. Wang, J. Dong, C. Xu, W.-D. Cao, and R. Kennedy

Press Forging of Alloy 718Plus™ (abstract only) ................................................................................... 709

J. Lemsky, K. Kloske, T. Bayha, and H. Sizek

IsoCon Processing of Alloy 718Plus™ (abstract only) ........................................................................... 711

J. Lemsky, K. Kloske, and T. Bayha

TTT Diagram of a Newly Developed Nickel-Base Superalloy – Allvac® 718plus™............................... 193

X. Xie, C. Xu, G. Wang, J. Dong, W.-D. Cao, and R. Kennedy

Evaluation of Allvac® 718Plus™ Alloy in the Cold Worked and Heat Treated

Condition ................................................................................................................................................. 203

B.J. Bond, and R.L. Kennedy

Application of Direct Aging to Allvac® 718plus™ Alloy for Improved Performance ............................... 213

W.-D. Cao, and R.L. Kennedy

Investment Casting of Allvac® 718Plus™ Alloy ..................................................................................... 223

T.D. Bayha, M. Lu, and K.E. Kloske

Effect of Thermal-Mechanical Treatment on the Fatigue Crack Propagation Behavior of

Newly Developed Allvac® 718plus™ Alloy............................................................................................. 233

X. Liu, J. Xu, N. Deem, K.-M. Chang, E. Barbero, W.-D. Cao,

R.L. Kennedy, and T. Carneiro

Properties and Microstructure of Allvac® 718plus™ Alloy Rolled Sheet................................................ 243

D.S. Bergstrom, and T.D. Bayha

Characteristics of VIM/VAR-Processed Alloy 718 Ingot and the Evolution of Microstructure

During Cogging ....................................................................................................................................... 253

N.-K. Park, J.-T. Yeom, J.-H. Kim, and X.-X. Cui

Modeling Microstructure Evolution in 718 Ingot to Billet Conversion (abstract only).............................. 713

W. Carden

Analysis of Microstructural Properties of IN718 After High Speed Forging............................................ 261

L. Renhof, C. Krempaszky, E. Werner, and M. Stockinger

vii

Effects of Large Reductions and Heating Temperature-Times on Grain Size Control of

Alloy 718 Rolled Rings............................................................................................................................ 679

J. Cardenas, H. Guajardo, C. Hardwood, and J.A. Manriquez

The Use and Performance of Wrought 625 Alloy in Primary Surface Recuperators for Gas

Turbine Engines...................................................................................................................................... 271

J.M. Rakowski, C.P. Stinner, M. Lipschutz, and J.P. Montague

The Effect of Nb, Ti, Al on Precipitation and Strengthening Behavior of 718 Type Superalloys............ 287

X. Xie, J. Dong, G. Wang, and W. You

The Precipitation of Primary Carbides in IN718 and Its Relation to Solidification Conditions ................ 299

A. Mitchell

The Effect of Cold Rolling on the Creep Behavior of INCONEL® Alloy 718 .......................................... 311

C.J. Boehlert, D.S. Dickmann, and N.C. Eisinger

Predicting Microstructural Transitions Via Computer Modeling and the Importance of Strain

and Temperature in IN718 Forging Design (abstract only) .................................................................... 715

A. Haynes, and T. Howson

Metallurgical Evaluation of Spray Deposited and Ring Rolled IN718..................................................... 321

G. Zhang, Z. Li, S. Tian, H. Yuan, R. Yao, Y. Zhang, Y. Zhao,

L. Guo, and M. Yan

A Microstructural Study of Alloy 718 Plus™ ........................................................................................... 329

J.F. Radavich, and T. Carneiro

Carbides and Their Influence on Notched Low Cycle Fatigue Behavior of Fine-Grained

IN718 Gas Turbine Disk Material............................................................................................................ 341

P.R. Bhowal, and A.M. Wusatowska-Sarnek

Effect of δ-Phase on the Weldability and The Hot Ductility of Alloy 718................................................. 351

G. Sjöberg, T. Antonsson, S. Azadian, R. Warren, and H. Fredriksson

High Temperature Hold Time Effects on Fine Grain Processed 718 Fatigue Properties

(abstract only) ......................................................................................................................................... 717

D. Greving, H. Kington, D. Rice, and B. Hann

Microstructure Development and Thermal Response of Delta Processed Billet and Bar for

Alloy 718 ................................................................................................................................................. 363

J.L. Russell, M.L. Lasonde, and L.A. Jackman

The Dynamic and Metadynamic Recrystallisation of IN718 ................................................................... 373

R.P. Guest, and S. Tin

Modelling Microstructural Transformations of Nickel Base Superalloy IN718 During Hot

Deformation............................................................................................................................................. 385

R.P. Guest, and S. Tin

viii

Influence of Phosphorus on Creep Performance of DA IN718............................................................... 687

J. Heaney, W. Buttrill, J. Russell, and P. Mrowczynski

Influence of Phosphorus on Deformation Mechanism and Mechanical Properties of IN718

Alloy ........................................................................................................................................................ 399

W.R. Sun, H.R. Guan, M. Wang, Z.G. Wang, L.F. Huang, and Z.Q. Hu

Alloys 625 and 725: Trends in Properties and Applications ...................................................................409

L.E. Shoemaker

Design of Alloy’s Concentrations for Optimized Strength, Temperature, Time-to-Rupture,

Cost and Weight...................................................................................................................................... 419

G.S. Dulikravich, and I.N. Egorov-Yegorov

Spray Forming and Post Processing of Superalloy Rings...................................................................... 429

M. Walter, M. Stockinger, J. Tockner, N. Ellendt, and V. Uhlenwinkel

A Unified Computer Model of the Spray Forming Process of Inconel 718 Rings................................... 441

I. Garmendia, A. Landaberea, T. Vicario, U. Fritsching, O. Belkessam,

P.S. Grant, and J. Mi

Sprayforming Optimisation of Superalloy Aeroengine Components ...................................................... 453

O. Caballero, D. Fournier, and W. Smarsly

Thermophysical Properties of IN738LC, MM247LC and CMSX-4 in the Liquid and High

Temperature Solid Phase ....................................................................................................................... 467

R.E. Aune, L. Battezzati, R. Brooks, I. Egry, H.-J Fecht, J.-P. Garandet,

M. Hayashi, K.C. Mills, A. Passerone, P.N. Quested, E. Ricci,

F. Schmidt-Hohagen, S. Seetharaman, B. Vinet, and R.K. Wunderlich

Microstructural Investigations of Electron Beam Welded Alloy 718 ....................................................... 477

M. Sundararaman, and P.J. Potdar

A Comparison of the Precipitation Kinetics of γ” Particles in Virgin and Re-Solutioned

Alloy 625 ................................................................................................................................................. 487

H.C. Pai, and M. Sundararaman

Notched Low Cycle Fatigue of Alloy 718 ................................................................................................ 497

A. Sridhar, V. Kumar, and A.K. Gogia

Properties of Bulk and Sheet Micro-, Submicro-, and Nanocrystalline Alloy 718................................... 507

S. Mukhtarov, V. Valitov, and N. Dudova

Characterization of Residual Stresses in Compressor Discs for Aeroengines:

Neutron Diffraction and Finite Element Simulations ............................................................................... 517

U. Cihak, M. Stockinger, P. Staron, J. Tockner, and H. Clemens

Residual Stresses in IN718 Turbine Disks ............................................................................................. 527

C. Krempaszky, E.A. Werner, and M. Stockinger

ix

Effect of Grain Size for the Tensile Strength and the Low Cycle Fatigue at Elevated

Temperature of Alloy 718 Cogged by Open Die Forging Press ............................................................. 539

Y.S. Song, M.R. Lee, and J.T. Kim

Influence of Portevin-Le Chatelier Effect on Rupture Mode of Alloy 718 Specimens ............................ 551

V. Garat, J-M. Cloue, B. Viguier, and E. Andrieu

High Temperature Intergranular Oxidation of Alloy 718 ......................................................................... 559

V. Garat, J. Deleume, J-M. Cloué, and E. Andrieu

Modelling the Material Properties and Behaviour of Ni- and NiFe-Based Superalloys .......................... 571

N. Saunders, Z. Guo, A.P. Miodownik, and J-Ph. Schillé

Effects of Cyclic Solution Treatment on the Microstructures and Mechanical Properties of

Alloy 718 ................................................................................................................................................. 581

J. Hong, J. Park, N. Park, S. Kim, and C. Kang

The Role of Oxygen-Grain-Boundary Diffusion During Intercrystalline Oxidation and

Intergranular Fatigue Crack Propagation in Alloy 718............................................................................ 591

E.-G. Wagenhuber, V.B. Trindade, and U. Krupp

A New Alloy Designed for Superheater Tubing in Coal-Fired Ultra Supercritical Boilers....................... 601

B.A. Baker

Material Properties Affecting the Machinability of Inconel 718 ............................................................... 613

M. Krook, V. Recina, and B. Karlsson

Design and Manufacture of a Very Large Hot-Gas Expander Impeller in Alloy 718 for

Highly Corrosive Off-Gas ........................................................................................................................ 629

S. Chandra, K.D. Mohr, and V. Schulte

HAZ Microfissuring in EB Welded Allvac 718 Plus™ Alloy..................................................................... 637

K.R. Vishwakarma, N.L. Richards, and M.C. Chaturvedi

Mixed Inconel® Alloy 718 Inertia Welds for Rotating Applications –

Microstructures and Mechanical Properties............................................................................................ 649

O. Roder, D. Helm, S. Neft, J. Albrecht, and G. Luetjering

Mechanical Properties of 718 Inertia Weld and Its Comparison with EBW............................................ 699

P.V. Neminathan, and T. Mohandas

Single Point Turning Process Optimization of Fine Grain Processed 718 (abstract only) ..................... 719

B. Hann, D. Greving, H. Kington, and D. Rice

Development of Forgeable Ni-Base Alloys for USC Steam Turbine Applications by Use of

Microstructure Simulation and Formability Testing................................................................................. 659

X. Li, R. Kopp, and M. Wolske

x

A Method of Optimizing Chemical Composition to Obtain Both Higher Strength and Higher

Plasticity for Alloy IN718C....................................................................................................................... 669

J. Zhao, and P. Yan

Creep-Testing Foils and Sheets of Alloy 625 for Microturbine Recuperators (abstract only)................. 721

N.D. Evans, P.J. Maziasz, and J.P. Shingledecker

Author Index............................................................................................................................................ 723

Subject Index .......................................................................................................................................... 727

xi

Preface

This Sixth International Symposium on Superalloys 718, 625, 706 and Derivatives

continues the great interest and activity in these most important materials for industrial

application. The First Symposium, held in 1989, was devoted to Alloy 718 and the

Second Symposium, held in 1991, extended the scope to include Alloy 625 from which

Alloy 718 was derived. Then, the Third Symposium, held in 1994, added Alloy 706, a

natural derivative of Alloy 718 which gained acceptance for land-based turbine rotors.

Finally, the Fourth and Fifth Symposia, held in 1997 and 2001, provided the recent

technology on the subject alloys.

The Sixth Symposium, held in 2005, covers the recent innovations in production,

processing, physical and mechanical metallurgy, and computer modeling. As seen in

the 2001 Proceedings, there were a large number of papers on processing, in particular,

forging practice. The trend continues in these Proceedings, with the latest information

on computer modeling as an added feature.

The tradition of having two invited overviews to begin the technical program continues

with the presentations by Richard L. Kennedy, Vice President, ATI Allvac, on the

newly developed Allvac 718 Plus, an improvement of Alloy 718. Indeed, the

considerable number of papers in the Proceedings can be considered a feature of the

Symposium. The second overview by Robin C. Schwant, Manager, Material

Engineering, GE Power Generation, provides the present status in developing Alloys

718 as an extension of Alloy 706 for heavy-duty turbine rotors in land-based turbines.

Seventy-five papers were accepted for the three day technical program and listed in the

familiar sequence. Noteworthy examples are probabilistic life of Alloy 718 for aircraft

engine disks, and modification of Alloy 706 for high temperature steam turbine rotors.

Also, recent information on Alloy 625 and 725 are presented which includes the use of

wrought 625 in primary surface recuperation for gas turbine engines.

Starting in 1989, the Editor initiated and organized each Symposium which included

program plan and publication of the Proceedings. It has been an arduous but engaging

task that I must relinquish because of my advanced age. I do hope that the effort will

continue in providing the latest technology on these most important superalloys.

E.A. Loria

Editor

xiii

Dedication

Edward A. Loria

All six Symposia on Superalloy 718, 625, 706 and Derivatives were organized by

Edward A. Loria over a sixteen year period, 1989-2005 and these Proceedings are

dedicated in honor of this achievement.

xv

Organizing Committee

E.A. Loria, Chairman

Consultant

G.D. Smith

Special Metals

R.E. Schafrik

GE Aircraft Engines

D.F. Paulonis

Pratt & Whitney

J.C. Schaeffer

GE Gas Trubine Operations

J.R. Groh

GE Aircraft Engines

J.J. Schirra

Pratt & Whitney

S.J. Balsone

GE Gas Trubine Operations

R.L. Kennedy

Allvac

B. Mueller

Howmet

S.J. Patel

Special Metals

D. Furrer

Ladish

G.E. Maurer

Carpenter Tech.

A. Mitchell

University of British Columbia

L.A. Jackman

Allvac

Corresponding Members

J-Y. Guedou

SNECMA

X. Xie

UST Beijing

J-F. Uginet

Aubert & Duval Holding

T. Carneiro

CBMM