Session: 18-04: Failure Prediction & Life Assessment I

Paper Number: 151561

Charpy Impact Testing of the Newly Developed High Gamma Prime Ni-Based LW LCT Superalloy for Qualification of 3D AM of Components for Petroleum and Natural Gas, Turbine Engines, and Aerospace Industries 

High gamma prime Ni-based superalloys have been used for manufacturing of turbine blades, nozzle guide vanes (NGV), combustion chambers, and stator components that are exposed to high temperature and stresses in service conditions for decades. Superior strength and creep properties of superalloys attributed to high volume fraction of Ni₃Al and Ni₃Ti gamma prime (γ’) phase, which affected weldability. For successful welding and 3D AM preheating of most commercially available Ni-based superalloys above 900°C is required complicating technology and increasing the cost of manufacturing. To simplify 3D AM of high temperature components, the weldable at ambient temperature LW LCT superalloy comprising 55 vol.% of γ’ phase was developed for 3D AM utilizing laser powder bed fusion (LPBF) and direct energy deposition (DED) as well as for repair of turbine engine components by manual GTAW. All components manufactured by LPBF and DED and joined by GTAW welding for the Petroleum and Natural Gas Industries in accordance with API 20S and ASME B31T standards respectively should be subjected to Charpy impact testing as per the ASTM E23 standard. However, Charpy testing has not been used for the characterization of superalloys due to high service temperature of turbine engine components and low ductility of high γ’ Ni-based superalloys at ambient temperature. Therefore, the current study was originated aiming to assess the applicability of the Charpy impact testing for characterisation and qualification of LW LCT GTAW welds and LPBF material for 3D AM of various components for the petroleum and natural gas, turbine engines, and aerospace applications. Charpy test results of Ni-based Haynes 230 annealed plate, cast equiaxed GTD111 superalloy, and single crystal PWA1484 material are also provided for comparability.

Presenting Author: Alexandre Gontcharov Liburdi Turbine Services

Presenting Author Biography: Dr. Alexandre B. Gontcharov Ph. D, Welding and Turbine Engine Repair Engineer with over 50 years of experience in welding and brazing of superalloys, refractory metals and alloys, single crystal and advanced materials for turbine engine applications, aerospace, nuclear, and petrochemical industries. Las 14 years has been working at Liburdi Turbine Services leading the development of new weldable high gamma prime Ni-based superalloys for repair and 3D AM of turbine engine components; co-author of over 70 inventions granted by patents and over 100 research papers published in various journals and conference proceedings.

Authors:

Mathieu Brochu McGill University
Alexandre Gontcharov Liburdi Turbine Services
Ashutosh Jena McGill University
Mudit Kesharwani McGill University
Paul Lowden Liburdi Turbine Services
Max Parthun Liburdi Turbine Services