Creep Behavior of High-

Temperature Material (Nickel-Based

Alloys for Aerospace and Gas Turbine Applications)
 CONTENT
Introduction

Creep Concept

Mechanism

Component level Test

Literature Survey and
Technological Gap
Future Scope

References
Introduction
The relentless pursuit of efficiency and performance in modern aerospace propulsion systems has pushed gas
turbine engines are engineered to operate under extreme thermal and mechanical stresses, with turbine inlet
temperatures reaching beyond 1500°C. However, components such as turbine discs, seals, and combustor liners
operate in the 600–750°C range, where creep deformation becomes a critical challenge. Understanding the
creep response of advanced nickel-based superalloys is essential to enhance component life, ensure engine
reliability, and push the limits of performance and efficiency. Under such extreme conditions, material
degradation mechanisms particularly creep, the time-dependent plastic deformation under constant stress—
become a dominant factor affecting the integrity, reliability, and lifespan of critical components.

Some important factor to be addressed are:

Operating Conditions:
•Gas turbine components experience temperatures: 600–750°C,
•Stresses: up to 600 MPa over service lives exceeding 10,000+ hours.
🔷 What is Creep?
•Creep is defined as the time-dependent, permanent deformation of a material under constant stress at high
temperatures, usually above 0.4–0.5 Tm (melting point).
•Unlike elastic or plastic deformation under short-term loading, creep occurs over long periods and is crucial in
high-temperature applications like aero engine turbines, combustors, and discs.
•It is characterized by a strain-time curve under constant stress and temperature.

📈 The Three Stages of Creep

🔹 Stage I: Primary (Transient) Creep

🔹 Stage II: Secondary (Steady-State) Creep

🔹 Stage III: Tertiary Creep

🔹 Stage I: Primary (Transient) Creep
• Primary creep is the initial stage of creep deformation that occurs immediately after the application of load
at elevated temperature.
• In this stage, the strain rate is high at first, but decreases with time due to work hardening of the material.
• The material’s internal resistance to deformation increases as dislocations multiply and interact, slowing
down further deformation.

🧪 Microstructural Insight Mechanisms involved:

During primary creep: •Dislocation glide
•Dislocation density increases rapidly. •Early dislocation multiplication
•Dislocations move and interact, forming tangles and substructures. •Limited dislocation climb
•In Ni-based superalloys (like IN718 and SU263), dislocations may •Initial grain boundary sliding
start bypassing or cutting through precipitates (γ′, γ″).
•Grain boundaries remain mostly stable, but minor sliding may
initiate at high temperatures.
🔹 Stage II: Secondary (Steady-State) Creep
• Stage II, also known as steady-state creep, is the longest and most important stage in creep life
prediction.
• During this phase, the strain rate remains nearly constant over time.
• A dynamic equilibrium exists between:
I. Work hardening (from continued deformation)
II. Recovery processes (like dislocation annihilation and climb)
 This stage is most relevant for engineering design, especially in components like turbine discs, seals, and
bolts, where long-term reliability at high temperatures is critical.

🧪 Microstructure Insight Mechanisms involved:

During Stage II:
•Dislocations rearrange into sub-grains or cell structures to minimize •Dislocation Climb
energy. •Dislocation Glide
•In Ni alloys like IN718 and SU263:
• γ′ precipitates act as barriers, requiring dislocations to climb or loop •Sub-grain Formation
around them (Orowan mechanism). •Grain Boundary Sliding (GBS)
• Recovery processes help maintain a steady dislocation density.
•Grain boundaries start to show minor sliding, but without cavitation.
🔹 Stage III: Tertiary Creep
• Tertiary creep is the final stage of the creep process, marked by a rapidly increasing strain rate that
ultimately leads to material rupture.
• Occurs after long exposure at high temperatures and stress.
• Characterized by damage accumulation, such as:
I. Grain boundary separation
II. Void and crack formation
III. Necking or localized thinning

🧪 Microstructural Insight (IN718 & SU263)

Mechanisms involved:
•INCONEL 718:
• Tertiary creep often initiates at δ-phase and Laves phase particles •Grain Boundary Sliding
at grain boundaries.
•Creep Cavitation
• Formation of micro voids and grain boundary cracks due to
phase instability. •Necking / Local Strain
•SU263:
•γ′ Coarsening (Ni alloys)
• Slower tertiary creep due to stable γ′ precipitate structure.
• Eventually, coarsening of γ′ and carbide particles leads to grain •Oxidation-assisted GB failure
boundary weakening.
🔹 Comparison of Mechanism Concepts

Aspect INCONEL 718 SU263

Strengthening Phases γ″ (primary), γ′ (minor) γ′ (primary, coherent, stable)
Glide; γ′ impedes dislocation
Primary Creep Dislocation glide + early hardening motion

Climb + Orowan looping; stable

Secondary Creep Climb over γ″, GB sliding begins
boundaries
Void formation at δ/Laves; GB
Tertiary Creep cracking γ′ coarsening; delayed cavitation

Grain Boundary Control Weak if δ-phase present Strong due to carbide stabilization

Max Use Temp (Creep) ~650–675°C ~750–770°C

Excellent (stable γ′ and GB
Creep Life Moderate (limited by δ/Laves) control)
🔍 Uniaxial vs. Multiaxial Creep Testing
 Uniaxial Creep Testing: Involves applying a constant load along one axis (usually tensile) while
maintaining a constant high temperature.

Test Setup: 📉 Outputs:

•Cylindrical or flat bar specimen •Strain vs. time curve → primary, secondary, tertiary creep
•Furnace or induction heater for uniform heating •Minimum creep rate (ε̇min)
•Strain measured using: •Rupture time (t/f)
• Extensometers •Stress exponent (n) and activation energy (Q) from
• Strain gauges models like Norton’s Law
• Digital Image Correlation (DIC)

✅ Advantages: ❌ Limitations:
•Easy to control and interpret •Does not represent actual component loading
•Standardized (ASTM E139, ISO 204) •Real-world stress states are rarely uniaxial
•Suitable for fundamental material behavior •No interaction between stress axes, i.e., no triaxiality
characterization effects
🔶 Multiaxial Creep Testing :
• Applies stress along two or more axes simultaneously (e.g., tension + torsion or hoop + axial).
• Reflects the true stress conditions found in complex components like turbine discs, combustion liners, or
seals.
 Multiaxial setups are essential for components
• Turbine discs (radial + hoop)
• Blade roots (bending + torsion)
• Combustion liners (internal pressure + axial)

🔩 Multiaxial Test Methods & Setup Designs 2. Biaxial (Cruciform Specimen) Test
1. Tension–Torsion Test 🔹 Purpose: Simultaneous biaxial (X and Y direction)
🔹 Purpose: Apply axial and shear stress together in-plane stresses
🔹 Setup Components: 🔹 Setup Components:
•Tubular specimen (hollow round bar) •Cruciform flat specimen
•Axial actuator applies tensile/compressive load •Independent actuators on both X and Y axes
•Rotational motor applies torsion (shear load) •Centre of specimen is heated (induction or laser heating)
•High-temp furnace (typically 650–800°C) •Strain measured by DIC or strain rosettes
•Extensometers or strain gauges for axial and shear strain 📍 Special Note:
•DIC (Digital Image Correlation) optional for full-field strain Cruciform setups are complex — alignment, load
mapping symmetry, and temperature uniformity are critical.
Internal Pressure Creep Test (Hoop Stress)
🔹 Purpose: Replicate hoop (circumferential) and radial stress as in pressure vessels or turbine casings
🔹 Setup Components:
•Thin-walled tubular specimen
•Sealed chamber with internal gas or oil pressure
•Heated externally via furnace or resistance coils
•Pressure regulator maintains constant stress
•Strain gauges around circumference measure hoop strain

Multi-Axial Bending + Tension Test

🔹 Purpose: Simulate blade root or bolt under thermal gradients
🔹 Setup:
•Beam-shaped specimen with loading arms on both ends
•Mid-span tension + ends under bending
•Used less often, but good for validation of FE models
 Literature Survey
INCONEL 718 — Creep Mechanisms and Coarsening Behaviour
•Gao et al. (1996) demonstrated preferential coarsening of γ″ (Ni₃Nb) precipitates during creep in IN718, showing oriented
growth variant selection under stress, a critical mechanism in creep softening.
•Chen et al. (1995) detailed the coarsening kinetics of γ″ precipitates in modified IN718, following Lifshitz-Slyozov-Wagner
theory and highlighting its impact on long-term creep properties
•Chaturvedi & Han (1983) covered precipitate–dislocation interactions, explaining how γ′ and γ″ influence creep resistance
via Orowan bypass and climb mechanisms
SU263 — High-Temperature γ′-Strengthened Alloy
•Floreen & Kane (1993) reported that SU263’s stable γ′ precipitation provides enhanced creep resistance up to 750 °C
•Carroll et al. (2017) confirmed that carbide-stabilized grain boundaries in SU263 effectively suppress void nucleation and
grain boundary sliding.
Component-Level & Multiaxial Creep
•Evans et al. (2008) highlighted the need for multiaxial testing in turbine disc evaluation, emphasizing limitations of
uniaxial creep extrapolation.
 Technology Gaps
Focus Area Identified Gap & Opportunity

Limited experimental data; need for tests on realistic geometries under combined loads
Multiaxial & Component Creep
(tension + hoop + shear).

Compared to IN718, SU263 lacks comprehensive creep studies — especially under

SU263 Experimental Data
multiaxial or service-like environments.

Absence of predictive models integrating γ′/γ″ coarsening, δ ‑phase, and cavitation

Microstructure–Life Modeling
effects, particularly for long-duration creep.

Need for tailored post-processing strategies (aging, HIP) specifically for SU263 and AM-
Heat Treatment Optimization
IN718 to balance strength and ductility over 10,000+ hrs.

Underdeveloped use of DIC, AE, X-ray CT for real-time monitoring of cavity/void

In-situ Damage Monitoring
initiation during component creep.

Promising preliminary results show AM-IN718 can match/exceed wrought; gaps remain
AM vs. Wrought IN718
in long-term (>10,000 hr) performance characterization.
 Future Scope for INCONEL 718
 Extension of Creep Data Beyond 650 °C:
 Most studies are limited to ~650 °C; further long-term testing (≥700 °C) is needed to understand failure mechanisms
like γ″ coarsening and δ-phase embrittlement.
• Evaluation of Additive Manufactured (AM) IN718:
• Investigate how microstructural anisotropy, residual stresses, and porosity in L-PBF or DED IN718 affect creep
behavior.
• Advanced Post-Processing Techniques:
• Develop tailored heat treatments (e.g., HIP + double aging) to optimize γ″ and reduce Laves/δ phase formation for
improved creep resistance.
• Multiaxial Creep Testing:
• Perform tests under torsion + tension or internal pressure conditions to simulate realistic engine stresses.
• In-situ Monitoring Techniques:
• Apply real-time strain tracking methods such as DIC or acoustic emission to capture early-stage damage during creep.
• Integration with Finite Element Modeling (FEM):
• Use validated creep data for advanced FE simulations to predict service life under complex loading and thermal
gradients.
• Comparative Study with Other Superalloys:
• Benchmark AM and wrought IN718 performance against advanced alloys like Alloy 625, 939, and SU263 under high-
temperature creep.
 Future Scope for SU263
• Expansion of Experimental Database:
• Currently underrepresented in literature—develop a comprehensive creep dataset across 650–800 °C and varying stress
regimes.
• Component-Level Testing:
• Test SU263 in real or scaled aero components (e.g., turbine disc or seal segment) to evaluate actual creep deformation
and damage zones.
• Multiaxial and Thermal Gradient Studies:
• Conduct experiments under multiaxial loads and controlled thermal cycling to assess long-term structural integrity.
• Effect of Grain Boundary Carbides and γ′ Stability:
• Study microstructural evolution (γ′ coarsening, carbide transformation) and its impact on tertiary creep and rupture life.
• Optimization for Additive Manufacturing:
• Explore the printability and post-processing of SU263 in AM formats and analyze its creep response compared to
wrought counterparts.
• Creep-Fatigue Interaction:
• Investigate creep-fatigue interaction under cyclic thermal-mechanical conditions representative of real gas turbine
operation.
• Modeling and Life Prediction:
• Develop or refine multiscale creep models incorporating SU263-specific microstructure evolution, especially γ′ kinetics
and cavity formation.
 Reference:
• Gao, M., Harlow, D.G., Wei, R.P. et al. Preferential coarsening ofγ″ precipitates in INCONEL 718 during creep. Metall Mater Trans
A 27, 3391–3398 (1996). https://doi.org/10.1007/BF02595432
• Coarsening behavior of γ″ precipitates in modified Inconel 718 superalloy. https://doi.org/10.1016/0956-716X(95)00446-3
• Effect of Heat Treatment on Creep Deformation and Fracture Properties for a Coarse-Grained Inconel 718 Manufactured by
Directed Energy Deposition doi.org/10.3390/ma16041377
• EFFECTS OF ETA PHASE ON CREEP PERFORMANCE OF THE NICKEL-BASE SUPERALLOY 263
10.31339/asm.cp.am-epri-2019p0621
• The Effect of η Phase Precipitates on the Creep Behavior of Alloy 263 and Variants doi.org/10.1016/j.msea.2020.140337