| Powder Metallurgy (P/M) processed nickel-base superalloys are used as turbine disk materials in jet engines. The P/M processing results in a homogenous microstructure. Large amounts of strengthening elements can be incorporated into the chemistry of these P/M alloys. In addition, the ability to produce near net-shaped parts with powder consolidation may offer the potential for large cost savings. However, the fatigue properties of P/M superalloys in the as-consolidated form have suffered because of the defect sensitivity of the as-consolidated microstructure. Expensive, thermomechanical steps are necessary to break down defects, so that the P/M parts can be considered defect-tolerant. As a result, the true potential cost savings for using P/M superalloys in turbines have never been realized.; This program was undertaken to examine the potential for utilizing an alternate heat treatment with P/M Alloy 720LI to generate a potentially defect-tolerant microstructure. This heat treatment had a soak above the gamma' solvus temperature followed by a controlled cool through the solvus. This produced gamma grains with a regular array of large dendritic-shaped secondary gamma' within the grains.; Mechanical testing was carried out to fully evaluate the effect of this alternate heat treatment on the mechanical properties of Alloy 720LI. The standard heat treatment had longer lifetimes at the lower stress range conditions during high cycle fatigue; however, the alternate heat treatment was superior at the highest stress range. Fracture analysis suggests that this is due to the grain size difference. During tensile testing, the standard heat treatment had higher yield and ultimate strengths but lower ductility than the alternate heat treatment. This is thought to be due to the larger amounts of tertiary gamma ' present in the microstructure produced by the standard heat treatment. Finally, the standard heat treatment had longer creep lifetimes at the lowest test temperature. The alternate heat treatment performed better at the higher test temperatures. While the microstructure did not improve the fatigue properties across the board, the improved understanding of the microstructural evolution during heat treatment will help in developing new heat treatments that may provide the defect-tolerance that is necessary. |
