Aero engine test experience with CMSX-4{reg_sign} alloy single-crystal turbine blades

Journal Article · Mon Apr 01 04:00:00 EST 1996 · Journal of Engineering for Gas Turbines and Power

DOI:https://doi.org/10.1115/1.2816600· OSTI ID:244711

Fullagar, K P.L.; Broomfield, R W; Hulands, M ^[1]; Harris, K; Erickson, G L; Sikkenga, S L ^[2]

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1. Rolls-Royce PLC, Derby (United Kingdom). Aerospace Group
2. Cannon-Muskegon Corp., Muskegon, MI (United States). SPS Technologies

A team approach involving a turbine engine company (Rolls-Royce), its single-crystal casting facilities, and a superalloy developer and ingot manufacturer (Cannon-Muskegon), utilizing the concepts of simultaneous engineering, has been used to develop CMSX-4 alloy successfully for turbine blade applications. CMSX-4 alloy is a second-generation nickel-base single-crystal superalloy containing 3 percent (wt) rhenium (Re) and 70 percent volume fraction of the coherent {gamma}{prime} precipitate strengthening phase. The paper details the single-crystal casting process and heat treatment manufacturing development for turbine blades in CMSX-4 alloy. Competitive single-crystal casting yields are being achieved in production and extensive vacuum heat treatment experience confirms CMSX-4 alloy to have a practical production solution heat treat/homogenization ``window.`` The creep-rupture data-base on CMSX-4 alloy now includes 325 data points from 17 heats including 3,630 kg (8,000 lb) production size heats. An appreciable portion of this data was machined-from-blade (MFB) properties, which indicate turbine blade component capabilities based on single-crystal casting process, component configuration, and heat treatment. The use of hot isostatic pressing (HIP) has been shown to eliminate single-crystal casting micropores, which along with the essential absence of {gamma}/{gamma}{prime} eutectic phase, carbides, stable oxide, nitride and sulfide inclusions, results in remarkably high mechanical fatigue properties, with smooth and particularly notched specimens. The Re addition has been shown not only to benefit creep and mechanical fatigue strength, but also bare oxidation, hot corrosion, and coating performance. The high level of balanced properties determined by extensive laboratory evaluation has been confirmed during engine testing of the Rolls-Royce Pegasus turbofan.

• Sponsoring Organization: USDOE
• OSTI ID: 244711
• Report Number(s): CONF-940626--
• Journal Information: Journal of Engineering for Gas Turbines and Power, Journal Name: Journal of Engineering for Gas Turbines and Power Journal Issue: 2 Vol. 118; ISSN 0742-4795; ISSN JETPEZ
• Country of Publication: United States
• Language: English

Related Subjects

33 ADVANCED PROPULSION SYSTEMS
36 MATERIALS SCIENCE
FABRICATION
HEAT RESISTANT MATERIALS
HEAT RESISTING ALLOYS
MACHINING
MANUFACTURING
MECHANICAL PROPERTIES
METALLURGICAL EFFECTS
MICROSTRUCTURE
MONOCRYSTALS
NICKEL BASE ALLOYS
PERFORMANCE
RHENIUM
RHENIUM ALLOYS
TURBINE BLADES
TURBOFAN ENGINES