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Freckles, one of the common defects in blades used in heavy duty gasturbines, hugely deteriorates blades mechanical properties and liability underservice conditions. Thermal-solutal convection theory is a widely adoptedformation mechanism but few solid experimental evidences were reported. Herefor the first time we systematically studied the microstructure of 117 grainsin freckle chains from four different Nickel-based superalloys of either singlecrystal or directionally solidified alloys. The relationship between theinternal stress and the misorientation throughout the freckle chains is studiedby means of state-of-the-art electron microscopy. All results give newexperimental proof to the theory of thermal-solutal convection, which isfurther supported by the fact that borides at the boundary are randomlyorientated to alloys. Our results enrich the methodology of freckle study,providing a new sight of the formation mechanism of casting defects.

New vision of convection induced freckle formation theory in Nickel-based superalloys by electron microscopy