Investigation of Hafnium Oxide Containing Zirconium in the Scaled Region on the Surface of As-Cast Nickel-Based Single Crystal Superalloy Turbine Blades

Surface scale is usually formed in the aerofoil part of as-cast nickel-based single crystal turbine blades by the strong interaction between the mould wall and the melt, and the subsequent oxidation of the fresh metallic surface of the casting. For better understanding of the scaling, the scaled region was investigated, and an interesting region containing hafnium oxides and a rhenium-rich particle was found. Generally, a continuous aluminium oxide layer was detected on the outer surface of the base material and covered the surface of an unscaled region. In contrast, there was no oxide on the surface of a scaled region, but it was replaced by several tiny particles remaining locally on the outer surface of the base material. SEM-EDX and TEM-EDX point analysis of these particles indicated not only the existence of high amounts of hafnium, but also several particles such as hafnium oxide, aluminium oxide, and even tiny metallic particles. Most of all, STEM-EDX point analysis clearly detected zirconium in the hafnium oxide. Furthermore, a rhenium-rich particle was also detected towards the outer surface of the base material, which suggested that the surface of the scaled region might be exposed to high enough temperatures to allow the diffusion of heavy alloying elements. Based on the observation, the formation mechanism of hafnium oxide containing zirconium and its meaning was discussed.