Microstructure and Mechanical Properties in Gamma(face-centered cubic) + Gamma Prime(L12) Precipitation-Strengthened Cobalt-based Superalloys

High-temperature structural alloys for aerospace and energy applications have long been dominated by Ni-based superalloys, whose high-temperature strength and creep resistance can be attributed to a two-phase microstructure consisting of a large volume fraction of ordered gamma'(L12)-precipitates embedded in a disordered gamma(f.c.c.)-matrix. These alloys exhibit excellent mechanical behavior and thermal stability, but after decades of incremental improvement, are nearing the theoretical limit of their operating temperatures. In 2006, an analogous gamma(f.c.c.) + gamma'(L12) microstructure was identified in the Co-Al-W ternary system with liquidus and solidus temperatures 50-150 °C higher than conventional Ni-based superalloys. The work herein focuses on assessing the effects of alloying additions on microstructure and mechanical behavior in an effort to lay the foundations for understanding this emerging alloy system.;A variety of Co-based superalloys are investigated in order to study fundamental materials properties and to address key engineering challenges. Coarsening rate constants and temporal exponents are measured for gamma'(L1 2)-precipitates in a ternary Co-Al-W alloy aged at 650 °C and 750 °C. A series of Co-Al-W-B-Zr alloys are cast to study the influence of segregation of B and Zr to grain boundaries (GBs) on mechanical properties. Co-Ni-Al-W-Ti alloys with various amounts of Al, W, and Ti are cast in order to fabricate Co-based superalloys with decreased density and increased gamma'(L1 2)-solvus temperature. 2-D dislocation dynamics modeling is employed to predict how gamma'(L12)-precipitate size and volume fraction affect the mechanical properties of Ni- and Co-based superalloys. Compositional information such as phase concentrations, partitioning behavior, and GB segregation are measured with local electrode atom probe (LEAP) tomography in alloys with fine microstructures and with scanning electron microscope (SEM) electron dispersive x-ray spectroscopy (EDS) in alloys with coarse microstructures. High-temperature mechanical properties are determined with compression creep at 850 °C and flow stress tests conducted between room temperature and 900 °C. gamma'(L12)-solvus temperature, as well as solidus and liquidus temperatures, are measured with differential thermal analysis (DTA).;B and Zr strongly segregate to GBs in Co-Al-W-B-Zr alloys. B additions of 0.05 at. % result in micron-sized GB-precipitates that improve creep strength by two orders of magnitude. Segregation of B or Zr in amounts where GB-precipitates do not form, have no effect on creep strength over a ternary Co-Al-W alloy. The concurrent addition of B and Zr improves creep strength, though to a lesser degree than in alloys containing GB-borides. Ti is an effective substitute for W and Al in Co-Ni-Al-W alloys where density is decreased by 9 % and solvus is increased to 1137 °C in a Co-10Ni-5Al-5W-8Ti at. % alloy compared to 982 °C in a Co-10Ni-9Al-9W at. % alloy. Further investigation of reducing W in a Co-10Ni-6Al-xW-6Ti at. % (x=6, 4, 2, 0) alloys ascertain that, with the addition of Ti, gamma'(L12)-precipitates can form in a wider composition range than in ternary Co-Al-W alloys. 2-D dislocation dynamics simulations are in good agreement with experimental measurements for binary Ni-Al and ternary Co-Al-W alloys. General trends in strengthening are captured for higher order Ni-Al-Cr and Ni-Al-Cr-W alloys.