Microstructure and wear behavior of IC10 directionally solidified superalloy repaired by directed energy deposition

doi:10.1016/j.jmst.2021.04.006

Abstract

Abstract:

Directed energy deposition has been used to repair superalloy components in aero engines and gas turbines. However, the microstructure and properties are generally inhomogeneous in components because of the different processing histories. Here, the microstructures and wear behavior of different zones (substrate, HAZ, and deposit) are investigated for the IC10 directionally solidified superalloy repaired by the directed energy deposition process. It is found that the microstructure of the deposited layers is strongly textured with a <001>-fiber texture in the building direction, and the texture intensity is continuously increased along the building direction. Two kinds of γ′ phase (primary and secondary γ′ phase) can be found in the heat-affected zone (HAZ), and the average size of primary γ′ phase is smaller than that in the substrate due to liquation. In the deposit layers, the size of γ′ phase is much smaller than those in the substrate and the primary γ′ phase of HAZ; both size and the fraction of the γ′ phase decreases with the increase of building height. The wear rate of the substrate is the smallest, indicating the best wear resistance; while the wear rate of HAZ is the largest, indicating the worst wear resistance in the repaired sample. The wear rates in the deposit layers increase from the bottom to the top zones, showing a decreasing wear resistance. Abrasive wear is found to be the dominant wear mechanism of the repaired alloy, and the resistance to which is closely related to the fraction of γ′ phase in the microstructure. The understanding of the influence of microstructure on wear resistance allows for a more informed application of inhomogeneous superalloy components repaired by directed energy deposition in industry.

Key words: Directed energy deposition, Directionally solidified superalloy, Microstructure, Wear behavior, Repairing

Guan Liu, Dong Du, Kaiming Wang, Ze Pu, Dongqi Zhang, Baohua Chang. Microstructure and wear behavior of IC10 directionally solidified superalloy repaired by directed energy deposition[J]. J. Mater. Sci. Technol., 2021, 93: 71-78.

Figures/Tables 11

Fig. 1. SEM image of the IC10 powders.

Table 1. Chemical compositions of the studied IC10 alloy (wt.%).

Co	Cr	Mo	W	Al	Ta	Hf	C	B	Ni
12.0	7.0	1.5	5.0	5.9	7.0	1.5	0.1	0.015	Bal.

Table 2. Laser processing parameters.

Parameters	Values
Scanning speed (mm/s)	6
Powder feeding rate (g/min)	8.9
Laser spot diameter (mm)	2
Focal length (mm)	+32

Fig. 2. (a) Optical micrograph [31] and (b) EBSD orientation map of the microstructure in the cross-section of repaired alloy; (c-e) PF (pole figure) maps taken from the zone C, D, and E, respectively.

Fig. 3. TEM micrograph of γ΄ phase at (a) the substrate, (b) heat-affected zone, (c) bottom zone, (d) middle zone, (e) top zone of the repaired IC10 alloy, (f) schematic diagram of zones.

Fig. 4. Fraction of γ΄ phase at different zones of the repaired alloy.

Fig. 5. SEM images of the carbides at the substrate (a), joint zone (b), bottom zone (c), middle zone (d), and top zone (e) of the repaired IC10 alloy.

Fig. 6. Three-dimensional (3D) wear track surface profiles of repaired alloy after sliding wear in different zones: (a) substrate; (b) heat-affected zone; (c) bottom zone; (d) middle zone; (e) top zone of deposition layers; (f) the interpretation of X and Y-axis. It is noted that SD and BD refer to the scanning direction and building direction, respectively.

Fig. 7. (a) Typical cross-sectional profiles of the wear tracks; (b) wear rate at different zones of the repaired alloy.

Fig. 8. Morphology of the sample surface after dry sliding wear: (a) substrate; (b) heat-affected zone; (c) bottom zone; (d) middle zone; (e) top zone of deposition layers; (f) enlarged figure of debris.

Fig. 9. Worn surface around carbides of the repaired alloy: (a) the large size carbide; (b) the small size carbide.

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