RECENT ADVANCES IN

CAST SX SUPERALLOYS

Jacqueline Wahl and Ken Harris

®
Cannon-Muskegon® Corporation
A PCC COMPANY

1
 Background
• Historically, significant advances in single crystal
alloy performance were attained due to rhenium
effects
• Extensive application of 2nd generation (3% Re)
alloys in the hot section of gas turbine engines
• Consequently, 2nd generation SX superalloys
serve as the benchmark for all subsequent SX
alloy developments

2
 New Alloy Developments
• Due to high cost & limited availability of Re, market
pull for improved SX superalloys with low or no Re
compared to 3% Re alloys
• Concurrently, demand for lower fuel burn & reduced
CO2 emissions requires higher temperature
capability beyond 2nd gen. SX alloys, targeting 3rd
generation (6-7% Re) SX alloys
• In response, CM has developed three new,
proprietary SX superalloys:
CMSX®-8 (1.5% Re)
CMSX®-7 (no Re)
CMSX-4® Plus (4.8% Re)

3
 CMSX-8 Alloy Development
Alloy Development Goals:
• Excellent high temperature creep-rupture and
LCF properties (targeting 2nd gen. alloy CMSX-4®)
while maintaining
• Oxidation properties/coating adherence
• Castability
• Phase Stability
With significantly reduced Re content

4
 CMSX-8 Nominal Chemistry
Alloy Cr Co Mo Ta W Re Al Ti Hf Ni
CMSX-3 8 5 0.6 6 8 -- 5.6 1.0 0.1 Bal
CMSX-7 6 10 0.6 9 9 -- 5.7 0.8 0.2 Bal
CMSX-8 5.4 10 0.6 8 8 1.5 5.7 0.7 0.2 Bal
CMSX-4 6.5 9.6 0.6 6.5 6.4 3 5.6 1.0 0.1 Bal

• Re, Ta, Mo, W – balanced for good creep-rupture properties

(with low Re content) and acceptable phase stability
• High Ta content for castability/freedom from freckling
• Cr, Co – adjusted for phase stability
• Al, Ti, Ta – target ~70% Vf γ’ phase
• High Al, low Mo (Ti addition) + Hf addition – improved bare
alloy oxidation/coating adherence
• Density: 8.85 gms/cm3
• DSC Solidus: 1338°C, Liquidus: 1389°C

5
 Rupture Life: CMSX-8 vs.
CMSX-4 & Rene’ N5/Rene’ N515

6
 Time to 1% Creep
CMSX-8 vs. CMSX-4

7
CMSX-8 Elevated Temperature
Stress-Rupture

8
 CMSX-8 Post-test Microstructure

Excellent phase stability/ negligible TCP

phase formation following 4060 hours
stress-rupture testing at 1121°C (2050°F)
9
 Alloy Modifications
• CMSX-8 [B/C] alloy
• Modified chemistry w/optimized additions of C, B
• Targeting improved low angle boundary (LAB)
grain defect accommodation for difficult to cast
(e.g., SX vane segments) and/or large industrial
gas turbine components
• Alloy property characterization shows creep-
rupture results consistent with standard CMSX-8
properties

10
 Rupture Life CMSX-8 [B/C] vs.
CMSX-4 & Rene’ N5/Rene’ N515

11
 CMSX-8 [B/C] Defect Tolerance
Defect tolerance assessed
on transverse specimens
machined across intentional
LAB/HAB sefects in seeded
bi-crystal slabs

12
 CMSX-7 Alloy Development
Alloy Development Goals:
• Improved mechanical properties over existing
non Re-bearing SX alloys
Balanced with
• Good solution heat treatment window
• Castability
• Phase Stability
• Improved oxidation properties/coating adherence

13
 CMSX-7 Nominal Chemistry
Alloy Cr Co Mo Ta W Re Al Ti Hf Ni
CMSX-3 8 5 0.6 6 8 -- 5.6 1.0 0.1 Bal
CMSX-7 6 10 0.6 9 9 -- 5.7 0.8 0.2 Bal
CMSX-8 5.4 10 0.6 8 8 1.5 5.7 0.7 0.2 Bal
CMSX-4 6.5 9.6 0.6 6.5 6.4 3 5.6 1.0 0.1 Bal

• Ta, Mo, W – balanced for improved creep-rupture properties

• High Ta content for castability/freedom from freckling
• Cr, Co – adjusted for phase stability
• Al, Ti, Ta – target ~70% Vf γ’ phase
• High Al, low Mo (+ Ti) + Hf addition – improved bare alloy
oxidation/coating adherence
• Density: 8.8 gms/cm3
• DSC Solidus: 1325°C, Liquidus: 1381°C

14
Rupture Life CMSX-7 vs. CMSX-2/3

15
Time to 1% Creep

16
 Rupture Life CMSX-7 vs.
CMSX-4 & Rene N5/Rene’ N515

17
 CMSX-7 Post-test Microstructure

Excellent phase stability/ minimal TCP

phase formation following 1176 hours
stress-rupture testing at 1093°C (2000°F)
18
 CMSX-4® Plus Alloy Development
Alloy Development Goals:
• Improved high temperature properties over
CMSX-4 alloy, approaching 3rd generation SX
(6-7% Re) alloys, but better all round properties
considering:
• Improved solution heat treatment capability
• No SRZ phase problems/coating compatibility
issues
• Improved oxidation/hot corrosion properties
• Lower Re content, cost & density

19
 CMSX-4® Plus Nominal Chemistry
Alloy Cr Co Mo Ta W Cb Re Al Ti Hf Ni
(Nb)
CMSX-8 5.4 10 0.6 8 8 -- 1.5 5.7 0.7 0.2 Bal
CMSX-4 6.5 9.6 0.6 6.5 6.4 -- 3 5.6 1.0 0.1 Bal
CMSX-4 Plus 3.5 10 0.6 8 6 -- 4.8 5.7 0.85 0.1 Bal
CMSX-10K 2 3 0.4 8 5 0.1 6 5.7 0.2 0.03 Bal

• Re increased for improved creep-rupture properties,

balanced against adverse effects of SRZ phase & TCP
phase formation
• High Ta content for castability/freedom from freckling
• Cr - adjusted for phase stability
• Ti increased for γ/γ’ mismatch & interfacial chemistry
• High Al, low Mo (+ Ti) + Hf addition – improved bare alloy
oxidation/coating adherence
• Density: 8.927 gms/cm3
• DSC Solidus: 1351°C, Liquidus: 1406°C
20
 CMSX-4 Plus Rupture Life
Comparison (hours)
Test Parameters CMSX-4 Plus CMSX-4 CMSX-8
517 MPa/913°C 216 52 67
(75 ksi/1675°F)
248MPa/982°C 615 275 236
(36 ksi/1800°F)
296 MPa/982°C 276 88 89
(43 ksi/1800°F)
248 MPa/1010°C 227 82 85
36 ksi/1850°F)
190 MPa/1050°C 231 90 81
(27.6 ksi/1922°F)
103 MPa/1121°C 662 640 293
(15 ksi/2050°F)

21
 Time to 1% & 2% Creep

Test Parameters CMSX4 Plus CMSX-4 CMSX-8

1% 2% 1% 2% 1% 2%
creep creep creep creep creep creep
248 MPa/982°C 374 416 125 160 116 136
(36 ksi/1800°F)
296 MPa/982°C 171 45 39
(43 ksi/1800°F)
248 MPa/1010°C 130 147 35 45 40 48
(36 ksi/1850°F)
190 MPa/1050°C 118 138 37 54 34 43
(27.6 ksi/1922°F)

22
CMSX-4 Plus Post-test Microstructure

Excellent phase stability/minimal TCP phase formation

following 1492 hours creep-rupture testing at 1050°C (1922°F)

23
 Re Effect (A. Giamei
SUPERALLOYS 2012)

Suggests linear relationship

with increasing Re

24
Re / Alloying Effects
CMSX® …. 8% Ta Alloys
500 36.0 ksi/1800°F (001)
(248 MPa/982°C)
450

CMSX-4® PLUS
400 MOD C

350
Time to 2.0% Creep (hrs)

CMSX-4 PLUS
MOD B
300

250
Suggests
CMSX-4® PLUS
MOD A
exponential
200
relationship with
increasing Re
150 • [CMSX-4® (6.5% Ta) ]
CMSX®-8
100

50

0 1 2 3 4 5 6
Re wt %
 CMSX-4 Plus vs. CMSX-10K
Test Parameters Alloy Time to Time to Time to
Rupture 1% creep 2% creep
248 MPa/982°C CMSX-4 Plus 615 374 416
(36 ksi/1800°F) CMSX-10K 718 390 459
103 MPa/1121°C CMSX-4 Plus 662 -- --
(15 ksi/2050°F) CMSX-10K 558 -- --

Alloy Density (RT) kg/dm3 (not density corrected)

AM1 8.59
CMSX-4 8.70
SC180 8.84
CMSX-4 Plus 8.927
PWA 1484 8.95
Rene’ N-6 8.97
CMSX-10K 9.05

26
CMSX-4 Plus Mod C performances under non-
isothermal creep conditions

J. Cormier
Institut Pprime, UPR CNRS 3346, ENSMA
1 avenue Clément Ader, BP 40109, 86961 Futuroscope Chasseneuil
France

27
Webex ANR VISCANOPOL
CMSX-4 Plus Mod C vs CMSX- 27
1. Materials and Specimen

For CMSX-4 Plus Mod C: CM Std heat treatment (Solution + Agings)

For CMSX-10K: RR Solution treatment + GFQ + Agings = 6h/1152 C/AQ + 24h/871
C/AQ + 30h/760 C/AQ
For CMSX-4: CM recommended ST and aging heat treatments

Mechanical polishing of the surface up to a SiC 4000 grade finish (longitudinal

polishing)

CMSX-4 Plus Mod C vs CMSX-10K vs CMSX-4

2. Tests

Creep under thermal cycling conditions under 120 MPa : 15 min/1050 C + 1 min/1100 C + 15 min/1050 C + 1 min/1150 C.
-1 -1
Heating/cooling rates : 2 C.s /10 C.s respectively

T (°C) 1’/1150 C

1’/1100 C

15’/1050 C 15’/1050 C

Temps

[Cormier et al. Phil. Mag. Let. 2010]

CMSX-4 Plus Mod C vs CMSX-10K vs CMSX-4

 2/2. Creep under thermal cycling – CMSX-4 Plus Mod C vs other SXs

25
CMSX-4 CM1

CMSX-4 CM2
20

CMSX-4 CM3
Creep strain (%)

CMSX-4 DB1
15

CMSX-10K K2

CMSX10K PCC1
10

CMSX10K PCC2

5 CMSX-4 Plus Mod C #1

CMSX-4 Plus Mod C #2

0
0 50 100 150 200 250 300

Time (h)

CMSX-4 Plus Mod C vs CMSX-10K vs CMSX-4

 2/2. Creep under thermal cycling – CMSX-4 Plus Mod C vs other SXs

CMSX-4 CM1
4,5

CMSX-4 CM2

3,5 CMSX-4 CM3

Creep strain (%)

CMSX-4 DB1

2,5
CMSX-10K K2

CMSX10K PCC1

1,5
CMSX10K PCC2

CMSX-4 Plus Mod C #1

0,5
CMSX-4 Plus Mod C #2

0 5 10 15 20 25 30 35 40 45 50
-0,5

Time (h)

CMSX-4 Plus Mod C vs CMSX-10K vs CMSX-4

3. Microstructure observations (’ in dark)
General aspect CMSX-4 CMSX-4 Plus Mod C CMSX-10K


the failur surface
1 mm away from
the failur surface
5 mm away from

A higher ’ volume fraction for CMSX-10K and CMSX-4 Plus Mod C

compared to CMSX-4 (in agreement with the ’ solvus temperature)

CMSX-4 Plus Mod C vs CMSX-10K vs CMSX-4 7

 2/5. Non isothermal creep performance (Number of thermal cycles up to failure)
1000 Mar-M200
René N4
MC2
Y scale logarithmic
AM3
AM1
René N5
100
CMSX-4
Cycles to failure

CMSX-10K
MCNG
CMSX-4 Plus Mod C

10

Very high temperature non-isothermal creep properties controlled by

the ’ solvus temperature
1
1190 1210 1230 1250 1270 1290 1310 1330 1350 1370
' solvus temperature (°C)

CMSX-4 Plus Mod C vs CMSX-10K vs CMSX-4

 Summary/Conclusions
• Single crystal alloy requirements for new engine
applications take into consideration both operating
conditions and market economy
• Newly developed SX superalloys offer improved properties
at reduced Re content:
– CMSX-8 similar to CMSX-4 to at least 1010°C (1850°F)
– CMSX-7 exceeds CMSX-2/3 to ~ 1038°C (1900°F) & similar to
Rene’ N5/Rene’ N515 published data
– CMSX-4 Plus approaches CMSX-10K properties
• These alloys demonstrate improved capability developed
with ~35 years of SX alloy/casting industrial experience

34