Comparative Analysis of Next-Gen Single-Crystal Nickel Superalloys for HPT Blades via FEM
DOI:
https://doi.org/10.3849/aimt.02004Keywords:
lightweight alloys, HPT blade, FEA, nickel-based superalloys, strain and deformation analysisAbstract
This study details a structural integrity evaluation of a high-pressure turbine (HPT) blade made up of three nickel-based single-crystal superalloys, specifically CMSX-4, CMSX-8, and CMSX-4 Plus. Finite element analysis was conducted to evaluate stress, strain, deformation, and safety factor under real thermal and mechanical loading. Aerodynamic precision was simulated in blade geometry, discretized using tetrahedral elements, and fixed root and surface pressure was applied. Material information was used from experimental sources. Results showed similar levels of stress for all alloys, but differences in strain and deformation were noted. CMSX-8 registered the lowest deformation and highest safety factor, indicating better mechanical performance and appropriateness as the material of choice for future high-performance turbine blades.
References
DUA, D., M. KHAJAVI, G. WHITE, D. THIRUMURTHY and J. SINGH. Stress Rupture Behavior of Disk Superalloys Exposed to Low-Temperature Hot Corrosion Environment. In: ASME Turbo Expo 2020: Turbomachinery Technical Conference and Exposition. New York: ASME, 2021. https://doi.org/10.1115/GT2020-14113.
ROZMUS-GÓRNIKOWSKA, M., J. KUSIŃSKI, Ł. CIENIEK and J. MORGIEL. The Microstructure and Properties of Laser Shock Peened CMSX-4 Superalloy. Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science, 2021, 52(7), pp. 2845-2858. https://doi.org/10.1007/s11661-021-06277-7.
CHAPMAN, N., S. GRAY, J. SUMNER and J. NICHOLLS. Stress Corrosion Testing of CMSX-4, CM247LC DS and IN6203DS Ni-Base Superalloys. Oxidation of Metals, 2021, 95(1-2), pp. 85-104. https://doi.org/10.1007/s11085-020-10011-w.
KUMAR, A., S. KUMAR and K.N. PANDEY. Life Prediction of C3X Gas Turbine Blade of CMSX-4 Material. Advances in Materials and Processing Technologies, 2022, 8(4), pp. 4156-4180. https://doi.org/10.1080/2374068X.2022.2039425.
LÉTANG, M., S. BJÖRKLUND, S. JOSHI, D. SEBOLD, O. GUILLON and R. VAẞEN. Repair of Single-Crystal CMSX-4 Using the High Velocity Air Fuel Process. Journal of Thermal Spray Technology, 2025, 34, pp. 1489-1506. https://doi.org/10.1007/s11666-025-01944-2.
DURST, K. and M. GÖKEN. Micromechanical Characterisation of the Influence of Rhenium on the Mechanical Properties in Nickel-Base Superalloys. Materials Science and Engineering: A, 2004, 387-389, pp. 312-316. https://doi.org/10.1016/j.msea.2004.03.079.
CHOI, B.G., C.Y. JO, H.U. HONG, I.S. KIM, S.M. SEO and H.M. KIM. Effect of Pre-Strain on Microstructural Evolution during Thermal Exposure of Single Crystal Superalloy CMSX-4. Transactions of Nonferrous Metals Society of China, 2011, 21(6), pp. 1291-1296. https://doi.org/10.1016/S1003-6326(11)60855-8.
XIA, W., et al. New Strategy to Improve the Overall Performance of Single-Crystal Superalloys by Designing a Bimodal γ′ Precipitation Microstructure. Acta Materialia, 2023, 257, 119200. https://doi.org/10.1016/j.actamat.2023.119200.
SHANG, Z., et al. Microstructure and Mechanical Properties of a New Nickel-Based Single Crystal Superalloy. Journal of Materials Research and Technology, 2020, 9(5), pp. 11641-11649. https://doi.org/10.1016/j.jmrt.2020.08.032.
SONG, Y., et al. New Insights into the Optimisation of the Solution Heat Treatment Process and Properties of CMSX-4 Superalloys. Materials Science and Engineering: A, 2024, 890, 145947. https://doi.org/10.1016/j.msea.2023.145947.
CHENG, Y., X. ZHAO, W. XIA, Q. YUE, Y. GU and Z. ZHANG. The Overview of the Formation Mechanisms of Topologically Close-Packed Phases in Ni-Based Single Crystal Superalloys. Materials and Design, 2024, 237, 112582. https://doi.org/10.1016/j.matdes.2023.112582.
WANG, T., et al. Effect of Temperature on Tensile Behavior, Fracture Morphology and Deformation Mechanisms of Nickel-Based Single Crystal CMSX-4. Journal of Alloys and Compounds, 2022, 912, 165175. https://doi.org/10.1016/j.jallcom.2022.165175.
LI, Y.M., et al. Carbon Addition and Temperature-Dependent Tensile Deformation Resistance and Capacity of a Low-Cost 3rd-Generation Ni-Based Single Crystal Superalloy. Materials Characterization, 2024, 210, 113794. https://doi.org/10.1016/j.matchar.2024.113794.
WIJEYERATNE, N., F. IRMAK, N. O’NORA and A.P. GORDON. A Comparative Study of Constitutive Modeling of an Aero-Engine Single Crystal Superalloy under Creep-Thermomechanical Fatigue. In: AIAA Science and Technology Forum and Exposition, AIAA SciTech Forum 2022. Reston: AIAA, 2022. https://doi.org/10.2514/6.2022-0629.
HARRIS, K. and S. CANNON. CMSX-4® Plus Single Crystal Alloy Development, Characterization and Application Development. In: Proceedings of the 13th International Symposium on Superalloys. Pittsburgh: The Minerals, Metals & Materials Society, 2016. https://doi.org/10.1002/9781119075646.ch3.
LI, D., et al. High Temperature Oxidation Behavior of Ni-Based Superalloy Nimonic 95 and the Effect of Pre-Oxidation Treatment. Vacuum, 2021, 194, 110582. https://doi.org/10.1016/j.vacuum.2021.110582.
TARASOV, D., A. TYAGUNOV and O. MILDER. Simulation of the Nickel Superalloys Solvus Temperature by the Deep Learning Artificial Neural Network with Differential Layer. In: AIP Conference Proceedings, 2022, 2611(1), 130008. https://doi.org/10.1063/5.0119488.
WU, R.T. and R.C. REED. On the Compatibility of Single Crystal Superalloys with a Thermal Barrier Coating System. Acta Materialia, 2008, 56(3), pp. 313-323. https://doi.org/10.1016/j.actamat.2007.07.057.
LI, D., et al. Long-Term Aging Behavior and Mechanism of CMSX-4 Nickel-Based Single Crystal Superalloy at 950 °C and 1050 °C. Journal of Alloys and Compounds, 2024, 1004, 175763. https://doi.org/10.1016/j.jallcom.2024.175763.
ESTRADA RODAS, E.A., S. GORGANNEJAD and R.W. NEU. Creep-Fatigue Behaviour of Single-Crystal Ni-Base Superalloy CMSX-8. Fatigue and Fracture of Engineering Materials and Structures, 2019, 42(9), pp. 2155-2171. https://doi.org/10.1111/ffe.13098.
KUKLA, D., M. KOPEC, R. SITEK, A. OLEJNIK, S. KACHEL and Ł. KISZKOWIAK. A Novel Method for High-Temperature Fatigue Testing of Nickel Superalloy Turbine Blades with Additional NDT Diagnostics. Materials, 2021, 14(6), 1392. https://doi.org/10.3390/ma14061392.
Downloads
Published
Issue
Section
Categories
License
Copyright (c) 2025 Advances in Military Technology
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
Authors who publish with this journal agree to the following terms:
1. Authors retain copyright and grant the journal right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
2. Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
3. Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) prior to and during the submission process, as it can lead to productive exchanges, as well as earlier and greater citation of published work.
Users can use, reuse and build upon the material published in the journal for any purpose, even commercially.
