Enhancing Economic Affordability of Aircraft Engines: Development of a Low-Cost Single Crystal Superalloy DD93 Containing 3 Wt.% Re, Designed to Meet Third-Generation Superalloys Properties

DevelopingSingle crystal superalloy novel and affordable Ni-based single crystalSingle crystal (SC) superalloysSuperalloys is crucial in order to address the escalating expense of advanced industrial aero-engines. The present work introduces a novel low-cost SC superalloySuperalloys DD93, designed to meet the performance requirements of third-generation superalloysSuperalloys, which have a Re content of only 3 wt.%. The alloy designAlloy design proceeded focusing on reducing the Re additionRe addition whilst still maintaining a high-temperatureHigh temperature capability at 1120 ℃. Comprehensive performance tests confirmed that DD93 has great microstructural stabilityMicrostructural stability, and its stress ruptureStress rupture properties and tensile strength are comparable to those of commercial third-generation SC superalloysSuperalloys. In addition, DD93 was evaluated and shown to have favorable fatigueFatigue strength, environmental resistance, coatingCoating compatibility, and castability. More importantly, the reduced Re content of 3 wt.% leads to a considerable cost reduction of almost 40% compared to CMSX-10 and René N6. The competitiveness of DD93 in terms of cost and mechanical propertiesMechanical properties improves the affordability of turbine bladesTurbine blades and shows promising prospects for its application in advancedLow-cost single crystal superalloy aero-engine turbine bladesTurbine blades.