NICKEL BASED SUPER ALLOY
SUBMITTED BY
LAVESH KUMAR(ME21201)
(Manufacturing Engg.)
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CONTENTS
INTRODUCTION OF ALLOY
SUPERALLOY AND ITS TYPE
NICKLE BASED SUPER ALLOY( PROPERTY, MICROSTRUCTURE &
STRENGTHNING MECHANISM)
RESEARCH PAPERS
PRACTICAL APPLICATION
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WHAT IS AN ALLOY
• You might see the word alloy described as a "mixture of metals", but
that's a little bit misleading because some alloys contain only one
metal.
• It's mixed in with other substances that are nonmetals (cast iron, for
example, is an alloy made of just one metal, iron, mixed with one
nonmetal, carbon).
• The best way to think of an alloy is as a material that's made up of at
least two different chemical elements, one of which is a metal.
• The most important metallic component of an alloy (often representing
90 percent or more of the material) is called the main metal, the parent
metal, or the base metal.
• The other components of an alloy (which are called alloying agents)
can be either metals or nonmetals and they're present in much smaller
quantities (sometimes less than 1 percent of the total).
• Although an alloy can sometimes be a compound (the elements it's
made from are chemically bonded together), it's usually a solid
solution (atoms of the elements are simply intermixed, like salt mixed
with water). 3
WHAT IS SUPER ALLOY
• A Superalloy is an alloy with the ability to operate at high
fraction(Generally at 0.7-0.8 times) of melting point temperature,
good surface stability, and corrosion and oxidation resistance.
• Superalloys develop high temperature strength through solid solution
strengthening and precipitation strengthening from secondary phase
precipitates such as gamma prime( γ’) and carbides
• Creep and oxidation resistance are the prime design criteria.
• The crystal structure is typically face-centered cubic (FCC)
austenitic.
• Superalloys are often cast as a single crystal, while grain
boundaries may provide strength at low temperatures, they decrease
creep resistance. 4
TYPES OF SUPER ALLOY
NICKEL BASED COBALT BASED
SUPERALLOY SUPERALLOY
TYPES OF
Composition: SUPERALLOY Composition:
38-76% Ni, 30-65% Co,
Up to 27% Cr, 19-30% Cr,
Up to 20% Co 35% Ni
Ex- Nemonic, Inconel,
Waspalloy
IRON BASED Composition:
SUPERALLOY 32-67% Fe,
9-38% Ni,
15-22% Cr
Ex- Incoloy Series
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NICKEL BASED SUPER ALLOY
• Ni-based superalloys are more strong and have more corrosion resistance.
• They are the most commonly used superalloys generally used above 500°C in
oxidizing and corrosive environment. Example: Turbine Blades.
• Ni used as a matrix for superalloy because of FCC structure (Provide Good
Ductility), low linear thermal coefficient of expansion, does not undergo phase
transformation up to Melting Point Temperature.
• The Ni-based superalloys contain high Cr with Ti & Al to form precipitates and
additions of Mo, Co, Fe, C.
• On the basis of variation of additional alloying elements Ni-based superalloys are
generally of three types :
i) Inconel:- Composition: 15% Cr - 6.75% Fe - 2.5% Ti - 0.8% Al - 0.85% Co
ii) Nimonic:- Composition: 20% Cr - 18% Co - 2.5% Ti - 1.5% Al - 0.05% C
iii) Waspalloy:- Composition: 19.5% Cr - 13.5% Co - 2% Fe - 4.25% Mo - 1.3%
Al- 3% Ti - 0.1% C
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PROPERTIES & MICROSTRUCTURE
γ-PHASE: The continuous matrix is a FCC Ni-
based austenitic phase (γ-phase) that usually
contains a high percentage of solid-solution
elements such as Co, Cr, Mo and W.
γ'-PHASE
The primary strengthening phase in Ni-based
superalloys is Ni3(A1, Ti) or the γ'-phase. It is a
coherently precipitating phase (i.e., the crystal
planes of the precipitate are in registry with the
γ-matrix) with an ordered FCC crystal structure.
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STRENGTHENING MECHANISMS :
There are three prior strengthening mechanisms for Ni-based superalloys;
Solid Solution Hardening
Coherent Precipitate Hardening
Hardening by Carbide precipitation on grain boundaries
Solid Solution Strengthening:
Cr, Mo, AI, Nb, Ti and other alloying elements go to the solution and replace the
solvent atoms in their lattice positions. So local stress fields are formed that interact
with those of the dislocations, impeding their motion and causing an increase in the
yield stress of the material, which results increase in strength of the material.
Precipitation Strengthening:
It happens mostly due to Al & Ti, when they form γ' or Ni3(A1,Ti) with the solvent
atoms. This γ' phase impede the movement of dislocations and defects in a crystal
lattice which leads to increase of strength.
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Hardening by Carbide Precipitates:
• Presence of carbide precipitates (like M23C6, M6C or MC) which are
hard and brittle in nature causes strengthening of superalloys.
• Oxide dispersion strengthening is another method of strengthening in
which Yttrium oxides are dispersed on the matrix making the material
suitable for high temperature applications.
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PAPER-1, An Experimental Study on Investigation of Machining of Nickel Based Super
Alloy 718
In this paper is an experimental study concerning the Chemical Composition of Inconel 718
machinability of super alloy 718 involving high speed
turning operation. Element Wt.%
Ceramic inserts under three different speeds with fixed Ni 60.69
feed and depth of cut.
Cr 16.14
The impacts of machining parameters on the tool wear
Mo 1.57
were studied using SEM micrographs.
The ceramic cutting tools were acutely affected by the Fe 17.68
cutting speeds as seen from the SEM and EDS Mn 0.24
analysis.
Al 0.16
The present work has unconcealed attention-grabbing
findings regarding the tool wear mechanisms with Ti 0.57
regard to the machining of nickel alloy 718. Nb 2.49
Ta 0.46 13
Microstructure of Nickel Based Alloy 718
Specimen:
A uniform round shape Inconel 718 bar
with 50 mm diameter and 400 mm length Experimental Setup Kirloskar Center Lathe Machine Tool
was used as base material work piece for
machining
Experimental conditions of tests of machining
tests.
Cutting Speed 145 m/min, 230 m/min, 360 m/min
Feed Rate 0.19 mm/min (Constant)
Depth of Cut 0.3 mm (Constant)
Duration of machining 3 min (Constant)
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Environment condition Dry
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SEM image for Al-Oxide insert. (a). Vc 145 m/min, d = 0.3 mm and f = 0.19 mm/rev. (b). Vc 230 m/min, d =
0.3 mm and f = 0.19 mm/rev. (c). Vc 360 m/min, d = 0.3 mm and f = 0.19 mm/rev
SEM image for mixed–Oxide insert. (a). Vc 145 m/min, d = 0.3 mm and f = 0.19 mm/rev. (b). Vc 230
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m/min, d = 0.3 mm and f = 0.19 mm/rev. (c). Vc 360 m/min, d = 0.3 mm and f = 0.19 mm/rev.
Conclusion
Flank wear increases with increase of cutting speed throughout for the all the
experiment of turning with alumina-based ceramic and mixed oxide ceramic
inserts.
Al oxide presented longer tool lives than mixed alumina-based ceramic cutting
tool although higher cutting speeds were used.
Flank wear in mixed-based ceramic cutting tool is more than the Al- oxide
ceramic inserts on machining of Nickel alloy 718
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PAPER-2, Corrosion Behavior of Multi-Layered Plasma Sprayed Gd2O3 Doped YSZ
Coating on Ni based Super Alloys
Nickel based superalloys are widely used in production of turbine blades. Although these
materials have acceptable mechanical properties at high temperatures, they do can operate up
to 700–800°C but corrode and oxidize at temperatures above this
Thermal barrier coating is used to safeguard the turbine blades at high temperatures.
Commonly Yttria stabilized Zirconia TBC System is employed. This thermal barrier coating
provides a great thermal and oxidation protection up to 1200 ° C and fails above this
temperature
In order to increase the oxidation resistance of nickel base superalloy, gadolinium oxide doped
yttria stabilized zirconia coating mixed in varying percentages is applied on the surface of
superalloy by air plasma spray coating process
The salt spray corrosion test is carried out to analyses the corrosion behaviour
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Experimental Procedure: Salt Spray Corrosion Test:
• Inconel-718 substrates of 120 mm 30 mm • The corrosion resistance of the metallic and
5 mm dimensions were cut using wire cut coated samples conducted as per the standard
electrical discharge machining due to its ASTM B117
minimum or negligible effects on the • ASTM B117 Salt Spray Corrosion Testing is used
material after cutting. primarily to compare the corrosion resistance of
• The substrates were grit blasted by using painted or metal coated samples
coarse alumina particles to achieve proper • This test is carried out by keeping the test
adhesion of coating materials samples in the salt spray chamber at an angle
• The ceramic material is instantly melted tilted to 10 from vertical
and accelerated towards the substrate. It • The salt spray chamber is sprayed by 5% of NaCl
rapidly solidifies as its impacts on the solution
surface of the alloy and adhere to the • The sprayed particles form as a fogy environment
surface forming a protective layer and keep the environment similar to marine
• NiCrAlY is used as the bond coat. environment
• The temperature inside the salt spray chamber is
maintained at 35°C. In this research, the all the
samples were kept for 500 hrs. 19
Salt spray Corrosion Test chamber
Coating Composition of the Substrates.
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Conclusion
The coated YSZ(Yttria Stabilized Zirconia) top coated sample showed more
corroded spots than other coated samples after the exposure of salt spray test
during visual observation.
The doping of Gd2O3 in the YSZ powder coatings increased the corrosion
resistance.
The multi layer coatings show higher corrosion resistance than single layer
coatings.
It is also noted that the intermediate layer of Gd2O3 doped YSZ showed higher
corrosion resistance than the doped top coat samples
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PRACTICAL APPLICATION
Engine Parts
• Owing to its excellent heat resistance, Nickel-Based Superalloys are perfect components for
high-speed and high-friction applications that generate heat. The material has found its way in
the manufacturing of engine parts and accessories for aircraft and aerospace equipment.
Combustion Chambers
• Combustion Vessels are expected to experience extremely high temperatures, and this is
where Ni-based alloys are best used.
Steam Turbines
• Similar to combustion equipment, steam turbine power plants require temperature-resistant
materials such as nickel-based superalloys to keep the system preserved and intact.
Nuclear Applications
• With the combination of corrosion resistance and material strength in the face of extreme
heat, this kind of superalloy works well in the nuclear industry. Some nuclear plants use
nickel-based superalloys for the reactor core, control rod, and similar parts.
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