A high thermal gradient directional solidification method for growing superalloy single crystals

The experiments here were conducted at withdrawal rates of 3 mm/min and 1 mm/min using a CMSX-6 and a CMSX-4 superalloy, respectively. The process was assessed in terms of the thermal gradient (GL), structural refinement, microsegregation and porosity distribution, and compared to those using a Bridgman process. The GL of the process was 200-236 K/cm, which was 10-12 times higher than that in the Bridgman process. A more refined microstructure was produced having average primary and secondary dendrite arm spacing values as low as 243 μm and 72 μm, as well as 272 μm and 76 μm in the CMSX-6 and the CMSX-4 castings, respectively. The diameter of γ′ phase in the dendrite core of CMSX-6 and CMSX-4 castings was reduced from 0.8 μm to 0.3 μm and from 1.2 μm to 0.6 μm, respectively. The average areas of (γ′ + γ) eutectic pools became smaller and more homogeneously distributed. The mean pore sizes in the castings were reduced by 57% and 43% for the CMSX-6 and CMSX-4 superalloys, respectively, and the area fractions of the pores in the CMSX-6 and CMSX-4 samples were 16% and 12% of those produced in the Bridgman samples. The segregation coefficients of the major alloying elements were closer to unity than those in the Bridgman process, which indicates that the composition distribution is more uniform.