上海交通大学：《材料应用和实践 Materials Applications and Practices》课程教学资源_MT333 Superalloys A-Materials & Applications in Aerospace

盒 AO TONG MT333 Materials Applications and Practice Superalloys in Aerospace MT333 Materials Applications Practice Prof.XiaoQi Chen A.1 Superalloys in Aerospace What to be covered: O TONG UR A.Superalloys and Applications B.Superalloys Additive Manufacturing C.Superalloys Subtractive Manufacturing References: 1.Li H.Z.,Chen,X.Q.,(2013)"Tool Condition Monitoring in Machining Superalloys",Aerospace Materials Handbook,Series:Advances in Materials Science and Engineering,Editor:Zhang S., Zhao D.,ISBN 978-1-4398-7329-8,CRC Press,Boca Raton,USA,pp.77-107. 2.Chen,X.Q.,Gong,Z.M.,Huang,H.,Ge,S.S..,Zhou,L.B.(2002),"Process Development,Approach for 3D Profile Grinding,Polishing"in Advanced Automation Techniques in Adaptive Material Processing,Eds:Chen,X.Q.,Devanathan,R.&Fong,A.M.,ISBN 981-02-4902-0,World Scientific, Singapore,pp.19-54. 3. Chen,X.Q.,Gong,Z.M.,Huang,H.,Ge,S.S..,Zhou,L.B.(2002),"Adaptive Robotic System for 3D Profile Grinding,Polishing"in Advanced Automation Techniques in Adaptive Material Processing,Eds:Chen,X.Q.,Devanathan,R.Fong,A.M.,ISBN 981-02-4902-0,World Scientific, Singapore,pp.55-90. MT333 Materials Applications&Practice Prof.XiaoQi Chen A.2

MT333 Materials Applications A.1 & Practice Prof. XiaoQi Chen MT333 Materials Applications and Practice Superalloys in Aerospace MT333 Materials Applications A.2 & Practice Prof. XiaoQi Chen Superalloys in Aerospace A. Superalloys and Applications B. Superalloys Additive Manufacturing C. Superalloys Subtractive Manufacturing 1. Li H. Z., Chen, X.Q., (2013) “Tool Condition Monitoring in Machining Superalloys”, Aerospace Materials Handbook, Series: Advances in Materials Science and Engineering, Editor: Zhang S., Zhao D., ISBN 978-1-4398-7329-8, CRC Press, Boca Raton, USA, pp. 77 – 107. 2. Chen, X.Q., Gong, Z.M., Huang, H., Ge, S.S.., Zhou, L.B. (2002), “Process Development, Approach for 3D Profile Grinding, Polishing” in Advanced Automation Techniques in Adaptive Material Processing, Eds: Chen, X.Q., Devanathan, R. & Fong, A.M., ISBN 981-02-4902-0, World Scientific, Singapore, pp. 19-54. 3. Chen, X.Q., Gong, Z.M., Huang, H., Ge, S.S.., Zhou, L.B. (2002), “Adaptive Robotic System for 3D Profile Grinding, Polishing” in Advanced Automation Techniques in Adaptive Material Processing, Eds: Chen, X.Q., Devanathan, R. & Fong, A.M., ISBN 981-02-4902-0, World Scientific, Singapore, pp. 55-90. What to be covered: References:

A.SUPERALLOYS APPLICATIONS HAO TO Learning Goals 1.Refresh materials classification and properties 2.Understand Superalloys Structure and Properties 3.Understand Superalloys Applications in Aerospace MT333 Materials Applications Practice Prof.XiaoQi Chen A.3 1.MATERIALS CLASSIFICATION PROPERTIES O TONG UND 。 PE,PMMA Polymers Nylon (PA) PS,PU,PVC PET,PEEK EP,NR Iron and Steels Composites Metals Aluminum and Alloys Copper and Alloys Titanium and Alloys GFRP Superalloys:Nickel-based, CFRP Cobalt-based alloys,etc. Ceramics Alumina Magnesia Silica Silicon Carbide Silicon Nitride Cement and Concrete MT333 Materials Applications&Practice Prof.XiaoQi Chen A.4

MT333 Materials Applications A.3 & Practice Prof. XiaoQi Chen A. SUPERALLOYS & APPLICATIONS 1. Refresh materials classification and properties 2. Understand Superalloys Structure and Properties 3. Understand Superalloys Applications in Aerospace Learning Goals MT333 Materials Applications A.4 & Practice Prof. XiaoQi Chen 1. MATERIALS CLASSIFICATION & PROPERTIES Composites Polymers Metals Ceramics • Alumina • Magnesia • Silica • Silicon Carbide • Silicon Nitride • Cement and Concrete • GFRP • CFRP • PE, PMMA • Nylon (PA) • PS, PU, PVC • PET, PEEK • EP, NR • Iron and Steels • Aluminum and Alloys • Copper and Alloys • Titanium and Alloys • Superalloys: Nickel-based, Cobalt-based alloys, etc

Classes of Property 歌 Economic Price and availability Recyclability General Physical Density Mechanical Modulus Yield and tensile strength Hardness Fracture toughness Fatigue strength Creep strength Damping Thermal Thermal conductivity Specific heat Thermal expansion coefficient Electrical and Resistivity Magnetic Dielectric constant Magnetic permeability Environmental Oxidation Interaction Corrosion Wear Production Ease of Manufacture Joining Finishing Aesthetic Color Texture MT333 Materials Applications Practice Feel A.5 Metals AO TONG Metals are typically split into ferrous (iron containing) and non-ferrous Most widely used metals are alloys except for aluminum and precious metals Metals are in general are good thermal and electrical conductors.Many metals are relatively strong and ductile at room temperature,and many maintain good strength even at high temperature. MT333 Materials Applications&Practice Prof.XiaoQi Chen A.6 国

MT333 Materials Applications A.5 & Practice Prof. XiaoQi Chen Classes of Property Economic Price and availability Recyclability General Physical Density Mechanical Modulus Yield and tensile strength Hardness Fracture toughness Fatigue strength Creep strength Damping Thermal Thermal conductivity Specific heat Thermal expansion coefficient Electrical and Magnetic Resistivity Dielectric constant Magnetic permeability Environmental Interaction Oxidation Corrosion Wear Production Ease of Manufacture Joining Finishing Aesthetic Color Texture Feel MT333 Materials Applications A.6 & Practice Prof. XiaoQi Chen Metals • Metals are typically split into ferrous (iron containing) and non-ferrous • Most widely used metals are alloys except for aluminum and precious metals • Metals are in general are good thermal and electrical conductors. Many metals are relatively strong and ductile at room temperature, and many maintain good strength even at high temperature

2.SUPERALLOYS The term "superalloy"was first used shortly after World War II to describe a group of alloys developed for use in turbosuperchargers and aircraft turbine engines that required high performance at elevated temperatures. A superalloy,or high-performance alloy,is an alloy able to withstand extreme temperatures that would destroy conventional metals like steel and aluminum. Properties: excellent mechanical strength and creep resistance at high temperatures, >good surface stability, and corrosion and oxidation resistance. Structure:typically an austenitic face-centered cubic crystal structure. Base alloying element:usually nickel,cobalt,or nickel-iron. Examples:Hastelloy,Inconel,Haynes alloys,Incoloy,MP98T, TMS alloys,and CMSX single crystal alloys. MT333 Materials Applications Practice Prof.XiaoQi Chen A.7 Inconel O TONG U Inconel:Ni-Cr Based superalloys Element (by mass) Inconel g Cr Nb Co Mn Cu Si PB 600 7214.0-17.06.0-10.0 0.5 0.5 0.150.015 617 44.2-56.0 20.0-24.0 8.0-10.0 10.0-15.0 0.5 0.5 0.8-1.5 0.6 0.5 0.15 0.015 0.0150.006 625 5820.0-23.0 8.0-10.03.15-4.15 0.5 0.4 0.4 0.5 0.1 0.015 0.015 690 59.5 % 9.2 0.35 0.01 0.02 0.35 0.019 0.003 71850.0-55.017.0-21.0 balance 2.8-3.3 4.75-5.5 0.35 02-0.8 0.65-1.15 0.35 0.08 0.015 0.0150.006 X-750 70 14.0-17.0 5.0-9.0 0.7-12 1 1 0.5 0.4-1.0 2.25-2.75 0.5 0.08 0.01 MT333 Materials Applications Practice Prof.XiaoQi Chen A.8

MT333 Materials Applications A.7 & Practice Prof. XiaoQi Chen 2. SUPERALLOYS • The term "superalloy" was first used shortly after World War II to describe a group of alloys developed for use in turbosuperchargers and aircraft turbine engines that required high performance at elevated temperatures. • A superalloy, or high-performance alloy, is an alloy able to withstand extreme temperatures that would destroy conventional metals like steel and aluminum. • Properties:  excellent mechanical strength and creep resistance at high temperatures,  good surface stability,  and corrosion and oxidation resistance. • Structure: typically an austenitic face-centered cubic crystal structure. • Base alloying element: usually nickel, cobalt, or nickel-iron. • Examples: Hastelloy, Inconel, Haynes alloys, Incoloy, MP98T, TMS alloys, and CMSX single crystal alloys. MT333 Materials Applications A.8 & Practice Prof. XiaoQi Chen Inconel Ni Cr Fe Mo Nb Co Mn Cu Al Ti Si C S P B 600 72 14.0–17.0 6.0–10.0 1 0.5 0.5 0.15 0.015 617 44.2–56.0 20.0–24.0 3 8.0–10.0 10.0–15.0 0.5 0.5 0.8–1.5 0.6 0.5 0.15 0.015 0.015 0.006 625 58 20.0–23.0 5 8.0–10.0 3.15–4.15 1 0.5 0.4 0.4 0.5 0.1 0.015 0.015 690 59.5 30 9.2 0.35 0.01 0.02 0.35 0.019 0.003 718 50.0–55.0 17.0–21.0 balance 2.8–3.3 4.75–5.5 1 0.35 0.2–0.8 0.65–1.15 0.3 0.35 0.08 0.015 0.015 0.006 X-750 70 14.0–17.0 5.0–9.0 0.7–1.2 1 1 0.5 0.4–1.0 2.25–2.75 0.5 0.08 0.01 Inconel Element (% by mass) Inconel: Ni-Cr Based superalloys

Superalloy Gamma (y):The continuous matrix is an face- centered-cubic (fcc)nickel-based phase that usually contains a high percentage of disordered solid-solution elements such as Co,Cr,Mo,and W. Gamma Prime (y'):The primary strengthening phase in nickel-based superalloys is Ni(Al,Ti).It is a coherently precipitating phase(i.e.,the crystal planes of the precipitate are in registry with the y matrix)with an ordered crystal structure.The close match in matrix/precipitate lattice parameter(~0-1%)combined with the chemical compatibility allows the y'to precipitate homogeneously throughout the matrix and have long-time stability MT333 Materials Applications Practice Prof.XiaoQi Chen A.9 Superalloys Mechanical Resistance vs.Temperature: O TONG U fragile R Super-alloy T The composite structure of superalloys(ie.coexistence of"soft" disordered y phase and "ordered"y'phase brings new mechanical properties together with a light material MT333 Materials Applications Practice Prof.XiaoQi Chen A.10

MT333 Materials Applications A.9 & Practice Prof. XiaoQi Chen  ’ Superalloy • Gamma (): The continuous matrix is an face￾centered-cubic (fcc) nickel-based phase that usually contains a high percentage of disordered solid-solution elements such as Co, Cr, Mo, and W. • Gamma Prime ('): The primary strengthening phase in nickel-based superalloys is Ni3(Al, Ti). It is a coherently precipitating phase (i.e., the crystal planes of the precipitate are in registry with the  matrix) with an ordered crystal structure. The close match in matrix/precipitate lattice parameter (~0-1%) combined with the chemical compatibility allows the  ' to precipitate homogeneously throughout the matrix and have long-time stability MT333 Materials Applications A.10 & Practice Prof. XiaoQi Chen Mechanical Resistance vs. Temperature: R T ’  fragile Super-alloy The composite structure of superalloys (ie. coexistence of “soft” disordered  phase and “ordered” ' phase brings new mechanical properties together with a light material The composite structure of superalloys (ie. coexistence of “soft” disordered  phase and “ordered” ' phase brings new mechanical properties together with a light material Superalloys

3.SUPERALLOYS APPLICATIONS IN 歌 AEROSPACE MAO TONG The range of applications for which superalloys are used has expanded to many other areas and now includes aircraft and land-based gas turbines, rocket engines,chemical,and petroleum plants They are particularly well suited for these demanding applications because of their ability to retain most of their strength even after long exposure times above650°C(1,200°F).Their versatility stems from the fact that they combine this high strength with good low-temperature ductility and excellent surface stability. MT333 Materials Applications Practice Prof.XiaoQi Chen A.11 Superalloys Applications O TONG UN Air Transport: reducing energy consumption increasing reliability improve mechanical properties with lighter materials 目Rolls-Royce RB211-524G/H MT333 Materials Applications&Practice Prof.XiaoQi Chen A.12

MT333 Materials Applications A.11 & Practice Prof. XiaoQi Chen 3. SUPERALLOYS APPLICATIONS IN AEROSPACE • The range of applications for which superalloys are used has expanded to many other areas and now includes aircraft and land-based gas turbines, rocket engines, chemical, and petroleum plants. • They are particularly well suited for these demanding applications because of their ability to retain most of their strength even after long exposure times above 650°C (1,200°F). Their versatility stems from the fact that they combine this high strength with good low-temperature ductility and excellent surface stability. MT333 Materials Applications A.12 & Practice Prof. XiaoQi Chen Air Transport:  reducing energy consumption  increasing reliability  improve mechanical properties with lighter materials Superalloys & Applications

Jet Engine 盒 iiutn MT333 Materials Applications Practice Prof.XiaoQi Chen A.13 Turbojet engine O TONG UN INTAKE COMPRESSION COMBUSTION EXHAUST Air Inlet Combustion Chambers Turbine Cold Section Hot Section MT333 Materials Applications&Practice Prof.XiaoQi Chen A.14

MT333 Materials Applications A.13 & Practice Prof. XiaoQi Chen Jet Engine MT333 Materials Applications A.14 & Practice Prof. XiaoQi Chen Turbojet engine

Jet Engine Thrust (Force in N) 歌 JIAO TO ONG UN Aerodynamics Engine pushed forward Flow pushed backward Jet Engine Newton's Third Law of Motion MT333 Materials Applications Practice Prof.XiaoQi Chen A.15 Turbojet engine thrust The net thrust(F)of a turbojet is given by: O TONG UN Fy =(mair+m fuel)ve-mair V where: riair the mass rate of air flow through the engine rirue=the mass rate of fuel flow entering the engine the velocity of the jet(the exhaust plume)and is assumed to be less than sonic velocity .the velocity of the air intake the true airspeed of the aircraft (mi air +ritue)ve=the nozzle gross thrust(F) m airv=the ram drag of the intake air MT333 Materials Applications Practice Prof.XiaoQi Chen A.16

MT333 Materials Applications A.15 & Practice Prof. XiaoQi Chen Jet Engine Thrust (Force in N) MT333 Materials Applications A.16 & Practice Prof. XiaoQi Chen Turbojet engine thrust where: ṁair = the mass rate of air flow through the engine ṁfuel = the mass rate of fuel flow entering the engine ve = the velocity of the jet (the exhaust plume) and is assumed to be less than sonic velocity v = the velocity of the air intake = the true airspeed of the aircraft (ṁair + ṁfuel)ve = the nozzle gross thrust (FG) ṁair v = the ram drag of the intake air The net thrust (FN) of a turbojet is given by: F m m v mair v e N air fuel     (  ) 

Turbojet engine thrust O TONG UN The rate of flow of fuel entering the engine is very small compared with the rate of flow of air.If the contribution of fuel to the nozzle gross thrust is ignored,the net thrust is: FN =mair (Ve-v) The velocity of the jet(ve)must exceed the true airspeed of the aircraft (v)if there is to be a net forward thrust on the aircraft.The velocity (ve) can be calculated thermodynamically based on adiabatic expansion. MT333 Materials Applications Practice Prof.XiaoQi Chen A17 Turbofan High-pressure High-pressure Fan compressor turbine High-pressure O TONG UN shaft Low-pressure shaft Low-pressure Combustion Low-pressure Nozzle compressor chamber turbine Turbofan's Bypass ratio(BPR):the ratio between the amount of air(kg)which bypasses the core of the engine and that passes through the core. Low bypass:2:1 or less. High bypass:4:1 to 8:1,Rolls-Royce Trent XWB approaching 10:1 MT333 Materials Applications Practice Prof.XiaoQi Chen A.18

MT333 Materials Applications A.17 & Practice Prof. XiaoQi Chen Turbojet engine thrust The rate of flow of fuel entering the engine is very small compared with the rate of flow of air. If the contribution of fuel to the nozzle gross thrust is ignored, the net thrust is: The velocity of the jet (ve) must exceed the true airspeed of the aircraft (v) if there is to be a net forward thrust on the aircraft. The velocity (ve) can be calculated thermodynamically based on adiabatic expansion. F m (v v) e N  air   MT333 Materials Applications A.18 & Practice Prof. XiaoQi Chen Turbofan • Turbofan’s Bypass ratio (BPR): the ratio between the amount of air (kg) which bypasses the core of the engine and that passes through the core. • Low bypass: 2:1 or less. • High bypass: 4:1 to 8:1, Rolls-Royce Trent XWB approaching 10:1

Turbofan jet engine thrust 盒 AO TO The net thrust(F)generated by a turbofan is ● Fy me ve-mo vo BPR(me v) m=the mass rate of hot combustion exhaust flow from the core engine mo=the mass rate of total air flow entering the turbofan mc+m mc=the mass rate of intake air that flows to the core engine m,=the mass rate of intake air that bypasses the core engine v;=the velocity of the air flow bypassed around the core engine ve=the velocity of the hot exhaust gas from the core engine vo=the velocity of the total air intake the true airspeed of the aircraft MT333 Materials Applications Practice Prof.XiaoQi Chen A.19 Turboprop jet engine Prop Gearbo以 Compressor Turbine Exhaust O TONG UN Shant Combustion chamber In turboprop engines,a portion of the engine's thrust is produced by spinning a propeller,rather than relying solely on high-speed jet exhaust.As their jet thrust is augmented by a propeller,turboprops are occasionally referred to as a type of hybrid jet engine. MT333 Materials Applications&Practice Prof.XiaoQi Chen A20

MT333 Materials Applications A.19 & Practice Prof. XiaoQi Chen Turbofan jet engine thrust The net thrust (FN) generated by a turbofan is ṁ e = the mass rate of hot combustion exhaust flow from the core engine ṁo = the mass rate of total air flow entering the turbofan = ṁc + ṁf ṁc = the mass rate of intake air that flows to the core engine ṁf = the mass rate of intake air that bypasses the core engine vf = the velocity of the air flow bypassed around the core engine ve = the velocity of the hot exhaust gas from the core engine vo = the velocity of the total air intake = the true airspeed of the aircraft ( )f c o o e FN me v m v BPR m v       MT333 Materials Applications A.20 & Practice Prof. XiaoQi Chen Turboprop jet engine In turboprop engines, a portion of the engine's thrust is produced by spinning a propeller, rather than relying solely on high-speed jet exhaust. As their jet thrust is augmented by a propeller, turboprops are occasionally referred to as a type of hybrid jet engine