The advantage of single crystals has been established for materials used at high temperatures. They are usually manufactured by directional solidification using a premanufactured seed crystal; however, the production of single crystals cannot only be relatively costly, but can even be impossible for some ceramic particle strengthened materials. Homogeneously incorporating thermally stable ceramic dispersoids in a metal melt is very difficult due to strong differences in densities between the two phases. Therefore, such materials are usually manufactured by powder metallurgy (PM), which generally produces ceramic dispersion strengthened alloys initially with an isotropic and fine grain structure. It is then necessary to complete a secondary recrystallization [1,2] of the initial PM material in order to achieve a coarse and elongated grain structure that has proven to show high temperature strength properties close to those of single crystals. [3,4] It should be pointed out that secondary recrystallizing such materials into a single crystal structure is generally too costly or even impossible due to pinning of grain boundaries at hardening particles or segregation of dispersoids. Furthermore, it is well known that not all grains grow into a coarse and elongated structure during secondary recrystallization. Rather, pockets of nonrecrystallized fine grains usually remain, which are then called recrystallization defects. Although the latter are readily recognized as preferred locations for initiation of high temperature damage and failure in ODS superalloys, [5,6] their effect on the actual deformation resistance and high temperature strength has barely been investigated. The present work closes this gap by assessing and quantifying the influence of recrystallization defects on the strength of an oxide dispersion and g 0 precipitation strengthened nickel base superalloy, PM 3030. It shows the dependence of this influence on temperature, recrystallization defect volume fraction, and grain size. The developed principle understanding can be very useful for economically achieving optimal properties. In fact, while completely eliminating recrysallization defects can be imperative for some critical applications, setting their maximal tolerated content too low can lead to unnecessary challenges for process control and excessive manufacturing costs for less critical applications.
Materials and Their ManufactureAn incompletely secondary recrystallized batch of PM 3030, a Ni-base superalloy manufactured by Plansee GmbH (Lechbruck, Germany), was investigated. The material was manufactured by the PM route. [7,8] Mechanical alloying (MA) [9,10] of prealloyed powders produced a homogeneous alloy containing a fine oxide dispersion; the nominal chemical composition of PM 3030 is 17Cr-2Mo-3.5W-2Ta-6.6Al-1.1Y 2 O 3 -bal. nickel. The mechanically alloyed powders were then compacted using hot isostatic pressing (HIP) and underwent a company specific thermomechanical treatment including hot extrusion to a final round bar with a diameter o...