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Single crystal (SC) Rene N4 aircraft engine turbine blade superalloy was converted to a directionally solidified (DS) alloy for latter-stage industrial gas turbine (IGT) buckets. The new alloy, called GTD444™, is being used in GE’s steam cooled MS7001H (7H) for 3 rd and 4 th stage turbine buckets, and in conventionally cooled MS7001FB (7FB) and MS9001FB (9FB) IGT’s for 2 nd & 3rd stage turbine buckets. The alloy was created primarily by the addition of Boron (B) to SC Rene N4, and the change to a heat treatment that includes a final hold at ~2280°F (1249°C) for full ’ solutioning. The investment casting processing included a major scale-up effort (from GE Aviation SC-size) up to ~36 inch (91 cm) long buckets, with a weight up to ~40 pounds (18 kg) each. The emphasis of the paper is on casting and alloy development, material characterization, and optimization of mechanical properties. The amount of B was optimized for casting yield (including the influence of solutioning temperature, grain boundary cracking and recrystallized grains), and longitudinal and transverse creep strength. As of 1/31/08, GTD444 alloy in the advanced machine fleet leader has passed 8,000 fired hours, which is considered an industry milestone.

Optimizing SC Ren� N4 Alloy for DS Aft-Stage Bucket Applications in Industrial Gas Turbines