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Sintering and Joining of Ni-Based Superalloys via FAST for Turbine Disc Applications

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Abstract

Turbine discs are currently made of nickel-based superalloys, known for their high strength and creep resistance at high temperatures. Turbine discs of dual microstructure, each tailored for different functions, allow for performance improvement and weight savings, but current methods of joining dissimilar nickel-based superalloys, such as friction welding, exhibit a heat-affected zone (HAZ) and localized melting at the interface, leading to weak bonding. Here, we demonstrate that field-assisted sintering technology (FAST) can be effective in sintering CM247LC powder to high relative density and in joining two dissimilar superalloys, CM247LC and Inconel 718 (IN718), by diffusion bonding without forming a heat-affected zone. The subscale tensile testing of this FAST-joined specimen resulted in failure through both the bonding zone and IN718; the yield strength (~ 348 MPa) is slighter higher than that of FAST-processed IN718, confirming successful joining by FAST.

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Acknowledgments

The authors would like to thank material donations from the Air Force Research Laboratory. The authors also would like to thank Petr Kolonin and Kevin Busko (ARL/PSU) for their technical assistance in FAST sintering and Donald Stiver (ARL/PSU) for his assistance in die design. This work was supported by the Government under Agreement No. W911W6-17-2-0003, through the Penn State Vertical Lift Research Center of Excellence. The U.S. Government is authorized to reproduce and distribute reprints for Government purposes notwithstanding any copyright notation thereon. The views and conclusions contained in this document are those of the authors and should not be interpreted as representing the official policies, either expressed or implied, of the Aviation Development Directorate or the U.S Government. This work was also partly supported by the Applied Research Laboratory at The Pennsylvania State University (ARL/PSU) through subcontract #S-143-000-001 under a UES, Inc. Phase II SBIR (FA8650-17-P-2024).

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Authors and Affiliations

  1. Department of Aerospace Engineering, The Pennsylvania State University, University Park, PA, 16802, USA

    Charis I. Lin & Namiko Yamamoto

  2. Applied Research Laboratory, The Pennsylvania State University, University Park, 16802, USA

    Sebastian J. Niuman & Jogender Singh

  3. Department of Mechanical and Nuclear Engineering, The Pennsylvania State University, University Park, 16802, USA

    Anil K. Kulkarni

  4. UES, Inc., Dayton, OH, 45432, USA

    Derek S. King

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  1. Charis I. Lin
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Correspondence to Charis I. Lin or Jogender Singh.

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Manuscript submitted February 6, 2019.

Appendix

Appendix

See Figures A1 and A2.

Fig. A1
figure 17

XRD plots of CM247LC powders before and after FAST sintering (45 MPa, 1225 °C, 15 min)

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Fig. A2
figure 18

Exemplary stress–strain plots of tensile testing

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Lin, C.I., Niuman, S.J., Kulkarni, A.K. et al. Sintering and Joining of Ni-Based Superalloys via FAST for Turbine Disc Applications. Metall Mater Trans A 51, 1353–1366 (2020). https://doi.org/10.1007/s11661-019-05600-7

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