Single-crystal superalloys (SX or SC superalloys) are formed as a single crystal using a modified version of the directional solidification technique, leaving no grain boundaries. The mechanical properties of most other alloys depend on the presence of grain boundaries, but at high temperatures, they participate in creep and require other mechanisms. In many such alloys, islands of an ordered intermetallic phase sit in a matrix of disordered phase, all with the same crystal lattice. This approximates the dislocation-pinning behavior of grain boundaries, without introducing any amorphous solid into the structure.
Single crystal (SX) superalloys have wide application in the high-pressure turbine section of aero- and industrial gas turbine engines due to the unique combination of properties and performance. Since introduction of single crystal casting technology, SX alloy development has focused on increased temperature capability, and major improvements in alloy performance are associated with rhenium (Re) and ruthenium (Ru).
The creep deformation behavior of superalloy single crystal is strongly temperature-, stress-, orientation- and alloy-dependent. For a single-crystal superalloy, three modes of creep deformation occur under regimes of different temperature and stress: rafting, tertiary, and primary. At low temperature (~750 °C), SX alloys exhibits mostly primary creep behavior. Matan et al. concluded that the extent of primary creep deformation depends strongly on the angle between the tensile axis and the <001>/<011> symmetry boundary. At temperatures above 850 °C, tertiary creep dominates and promotes strain softening behavior. When temperature exceeds 1000 °C, the rafting effect is prevalent where cubic particles transform into flat shapes under tensile stress. The rafts form perpendicular to the tensile axis, since γ phase is transported out of the vertical channels and into the horizontal ones. Reed et al. studied unaxial creep deformation of <001> oriented CMSX-4 single crystal superalloy at 1105 °C and 100 MPa. They reported that rafting is beneficial to creep life since it delays evolution of creep strain. In addition, rafting occurs quickly and suppresses the accumulation of creep strain until a critical strain is reached.