‘Specification No. EWR-GT-00:/01-02 22 23 24 25 26 27 28 clpar, Archi chief, + Originee! MATERIAL SPECIFICATION FOR INVESTMENT CASTINGS OF INTBLC ALLOY FOR ARR TYPE 11D STAGE T AND ‘TURBINE BLADES AND VANES score “This speciation defines he minimum equrmtens for hot ssl pressed invesinent. castings manufacture! fom Phacomp contled Ness Superalloy INTBELC (Law Carbon ‘Varieiy) (63Ni 16Cr 8.5Co 3.5AL 3.5Ti 2.6W 1.8Mo 0.9Cb) for use as rotating blades of stationary vanes for we in ABB type LID ga turbines, DEFINITIONS 25 MEI 1999 ‘Master Heat, ‘The metal of a single furnace charge melted and east into ingot under vacuum, Lat ‘A group of componesis cst from the same master heat and processed through the same HIP and heat treatment eye ‘HIP Hot isostatic pres ELBLL Fluorescent Penetant Inspection 18s) Grains having a leg to width ratio greater than 4:1 and length greater than 6.5 mm (0.25 jn), ‘Linear Indications Indications having a length to width rato of 3:1 or greater ‘Throuzh-Going Indications TIncicaions appearing directly opposite each other and apparently extending through the casting. Melt A group of eastings produced from master heat ingot, r-nicied wn! poured under vaeuvin, ‘without loss of vacuum, wrSpecification No, EWR-GT-COVO1-02 a 32. 5a APPLICABLE DOCUMENTS ‘The following documents form a part of this specification to the extent specified herein Unless otherwise specified, the latest issue shall apply. U. S. Miltary Specification MIL-1-68663 “Taspection, Liguid Peneeant™ US. Military Specifeation MST 453C “Inspection, Radiographic” ‘ASTM E165 "Standard Practice for Liquid Peneteant Inspection Method” Asta 334 “Sundae Gide for Radigripie Tesing™ Asmat e139 pe "Slandard Practice for Conducting Creep, crbbyhusiice Mealie Matra: oo ie asm rit2 iandard Test Metheds for Determining Average Grain size" ASNT Recommended Practice No. SNT-TC-1A, "Personnel Qualificaton and Certification in Nondestrvetive Testing” recedence of documents, ‘Specific requirements contained in purchase order instructions or deawings may be issued to supplement the requirements ofthis decument. In cases of confit, the purchase order shall ake precedence followed by applicable drawings, followed by the document, GENERAL REQUIREMENT ‘TECHNICAL REQUIREMENTS ‘Composition ‘The composition ofthe master heat and castings shall conform tothe requirements of Table 1. aidtinn the maser beat shall conform t0 the requirements of Table I S.L.1 Gas contents should be limited t0 25 ppm Oxygen and 50 ppm Nitrogen. 2ofttSpecification No, EWR-GT-001/01-02 5.2 Sigma Control, ‘The average clectron vacancy number Ny 3M of the residoal gamma mate shall be calculated for each melt vsing a technique Ydemified in the process plan of the concerned foundry or calculations made in accordance with procedure given in Appendix I, INCO ‘Technieal Data, Alloy IN738, Ny shall not exceed 2.36, 5.2.1, Master heat Qualifienions: It is tobe done based on chemical composition, electron vacancy number and mechanical properties obtained oncast-1o-size bars after earryngout solution treatment and ageing eycles as per clause 5.4.1 5.2.1.1: Tens ‘minimum ‘Test Temperature (°C) | Tensile Strength | 0.2% Yield | SeElongation | Reduction (pay Strength (MPa) | (4xde) | in area ® ‘Room Temperature (25°C) | #25 0 3 3 650°C 80 5.2.1.2, Stresemptuce Propeties (Minimum) ‘Stress (MPa) ‘Elongation | Reduction (4x40) | inarea ey 980°C. 150 20 5 10 ‘Test Temperature (7C) 5.2.1.3. Hardness, Rockwell C: 30 to 40 5.3 Non-Destructive Testing Acceptance Limits 5.3.1 Cracks, cold shuts, srinkage and linear indications are not permitted. No through going indications aze permite 5.3.2. Non destructive testing atceptance limits shall be as identified onthe figures attached as ‘Appendix I. 533 ‘The castings shall be clean and free from blow holes, porosity, slag, oxides, cracks, sams, paring lies, and other injurious imperfections which will mately affect the operations Of the part or indicate use of inferior metal or casing techniques and shall comply with surface roughness requirements indicated on applicable drawings. wr Botti a .‘Specification No, EWR-GT-OO1/01-02 5.4 Mechanical Propentiss, 5.4.1 Afler HIP'ing, material for testing of mechanical properties shall be subjected to the following heat icearent in vacuum prior to testing Solution heat treatment: 1120 & 10°C (2050°F + 20°F) for 2 hours + 10 minutes and gas ‘quench a arate nat les than 40°Cmin up to 540°C. Cooling below 540°C can be done a, any convenient rate. Precipitation heat treatment (Ageing): 845°C 4 10°C (1550°P 4 25°F) for 24 hours and ‘ges quench at arate ot less than 15°C/min upto $40°C, then cool at any convenient at 5.4.2 Tensile properties of bars of 4 mm (0.160") minimum diameter shall meet the folowing rminimum requirements when tested according to ASTM E-8 ala test temperature of 619 + 3°C (1200 + "FY: Ulimate Tensile Strength 792 MPa (115,000 psi) (0.2% Offset Yield Szengih 68° MPa (100,000 psi) "6 Elongation ind d 38 Reduction of Area 38 5.4.3. Stress rupture properties of bars of 4.0 mm (0,160") minimum diameter shall mest the fellowing minimum requirements when tested in pairs according 10 ASTM E-139 at a temperature of 760°C ++ 3°C (I400°F + 5°F) using a minimum stress level of 585 MP2 (85,000 ps), Life 23 hours Rupture life: 30 hours Elongation in 4 ¢ 5% BE s Redvetion of Area () 5% mRA 10 [the stess rupture tars fil these requirements, two more specimens shall be cut and tested to the same equirerents. Failure ofthe second se of specimenssallsbjet the entire lot to rejection cclpenesnal at 5.5 Microsnitural Reasiments 5.5.1 Grain Sizes yey ‘The casting shall exhibit substantially unif6fm equiaxed grains of ASTM macro grain size MT io M6 ia airfoil sections andl ASTM macro grain sie MS or smaller in othe sections as measured in accordance with ASTM E12. No column grains ae allowed, except in pated ares. 5.5.2, Microporosity ‘Microperosity on the order of 4 to 7% is permitted inthe microstructure before HIP‘ing “The casting shall be free from blowholes, porosity, slg, oxides, cracks, seams or other Imperfections, After HIP'ing, the mlcroporesity skal be brought down io less than 0.3%. 5.5.3 Alloy depletion, oxidation and nitriding atthe surface ofthe components shall not exceed (0.025 mm (0.001 ive). Tnvergranular attack at the surface of the components shall not exceed 0,012 mm (0.0005 inc. wa 4ofit yh‘Specification No, EWR-GT-001/01-02 6 61 62 62.1 622 62.3 6.2.4 625 63 63. 632 64 641 6.42 PROCESSING REQUIREMENTS Al process procedures applied during the manufacture ofthe components shall be the same as those used in the reparation of first article qualification samples and described in the process plan as specifed in paragraph 7.1.2. Casting Process Revert shall not be remelted dicetly into castings. It may be weed for the preparation of raster heals. Castings shall be produced by the investment casting process, ftom master heat ingot, re- melted and poured unier vacuum without loss of vacuum between melting and pouting. No repair of castings for solating turbine components by welding or plugging is allowed, Repair of slator castings is allowed only with the prior written authorization ofthe purchaser for the specific repair proposed. For rotating blades, mo gating is permilted within 5 mm (0.2 inch) of loaded root surfaces (identified as Zone Tin the figures in Appendix 1. ‘All the production easings shall be despatched from the e yg 8 tern na ‘Sto read codon ie ‘atic! Requiremets a ‘Master heats shall be chemically analyzed for cdAformance with 5.1 From each melt a repesenatve analytical sample shall be cast and retained fora minimum petiod of seven years. The first melt ast froma master heat shall be tested for conformance With 5.1 and $.2. Subsequent melts shall be qualitatively analyzed to ensure thatthe correct material has been used resHIP Qualification These tess to be completed priar to HIP processing) “The purchaser shall be given prior notification ofall pre-HIP qualification inspections and allowed to witness all inspetions atthe place of manufacture. This requirement may only bbe waived with specif writen authorization from the purchaser. ‘All castings shall be radiogiaphed following the procedures eutlined in U.S. Military ‘Specification MST 453C or ASTM E94 to the acceptance limits defined in 5.3 and Appendix 1. Pars containing detets which willbe removed by machining ae not sbject to rejection. Such parts must be rezadiographed after machining prior to aeceptance ‘Ata random sunplng level of one casting per 100 and one casting per heat, metallographic ‘sections shall be prepared from the components as indicated on the figures attached as ‘Appendix Il, The secions shall be evaluated for compliance with 5.5.1 and 5.5.2. w Botti‘Specification No, EWR-GT-ODU01-02 644 65 65.1 652 653 65.4 66 6.6.1 662 67 671 673 Castings shall be etced for grain size deter sampling ata rate of one casting per mould sion and compliance with 5.5 by random Hot fssttie Pressing Fixture castings using nickel or iron base fixture materials with the pars supported uniformly to prevent distortion. Avoid supporting the parts by any thin seeons. The castings shall be processed at a temperature of 1204 *C & 15°C (2200 *F) + 25°F for a petiod of 2 104 hhours at a minimum pressure of 103 MPa (15,000 ps). Coal ata rate of 1.5 to 5°C per minute (3 t0 10°F pet minute) to below 1000 °C. If these cooling rates ace Act achievable in the HIP vessel, the following heat treatment may be carried out in vacuum in lieu of controlled cooling inthe HIP vessel; heat to 1204 "Ct 13°C (2000 *F) + 25°F for 2 hhours at 10 minutes and furnace cool ata rte of 1.5 to S°C per minute Q to 10°F per ‘minute) to below 1000°C. ‘The inert gas used mst contsin no greater than 35 ppm impurities and the atmosphere must be of suficient purity that te requirements of $5.3 are met. ‘After HIP'ing the castings shall be solution teated before despatching to the machine shop. ‘Sample castings shall however be subjected to the complete heat treatment solution heat featment and aging) asp the requirement and tesed to mone aly pecs deed inthis specification, oxt-HIP Qualification (These tess to be completes HIP processing (These tests to be exer Processing) Each Jot of castings shall be accompanied through IP by atleast six separstely cast test bars. After processing according to 5.4.1, thre ofthe bats shall be teste for compliance wih 5.4.2 and 5.4.3, Thee of the bars shall be delivered with the finished components. ‘Additional test bars nay be required as indicated by the purchase order. ‘At a random sampling level of one casting per 100 end one casting per heat, bas shall be ‘machined from the components as indicated inthe figures stached a8 Appendix I, After processing according 1054.1, the bars shall be tested for compliance with $.4.2 and $4.3, Final Qualification ‘These tests to be completed afterall casting process 1é machining is completed, ‘The purchaser shall be given prior notification of all fra qualification inspection allowed to witness all final inpectons at the place of manufzcturer, Tis requirement may only be ‘waived with specific writen authorization from EWR. ‘All castings shall be vigually examined for compliance wth $1 and the drawing ‘requirements prior to etching. All castings shall be Muorescen penetan inspected for conformance with 5.3, following procedures oulined ia the U.S. Military Speiieation MIL-1-6866B using method Type 1, ‘A,B, Cor Do fllewing procedures outined in ASTM E165 using method A, Type 1,3 w oft ye .Specification No, EWR-GT-001/01-02 614 615 68 12 724 ‘or 3 with a level 3 sensitivity penetrant. Prior to examination, the components must be in a thermally or chemically etched condition, Examination ofthe componeats ina grit blasted ‘condition is not allowed. ‘Ata sampling level 0 one casting per 100 and one casting per heat, metallurgical sections shall be emoved from the components as indicated on the figures atached as Appendix I ‘The samples shall be evaluated for compliance with 5.5. ‘The components shall be dimensionally tested in accordance with the engineering drawing, ‘dentfication ‘All components stall have a unique serial number, the heat code and supplier number applied. QUALITY REQUIREMENTS AND APPROVAL ‘Vendor & Personnel Qualification Aualts Prior to placing an over of any sort with a specific vendo, the vendor's facilities, quality control system, and general operation shall be audited for capability to adequately provide castings by represeatatve(s) from the purchaser. Approval shall be granted for a period speed bythe puree, but may be removed By the pusher agequate vendor performance at any tine Pecsonnel Qualiicatica ww Inspection personnel shall be qualified to ASNDT' Recommended Practice No, SNT-TC-1A, Level I, I or II. Personnel with Level I qualifications shall work under the supervision of aa Level Il or Level Il inspector. ‘Technical Review ane First Anil Inspection For each specific component, the vendor wil be required to submit a detailed process plan to the purchaser for review. This proces plan shall include detaled procedures for master heat procurement, mould preparation, casting, cove removal, chemical analysis, Ny3@ calculation, HIP processing, heat treatment, fluorescent penevant inspection, radiography, ‘rain size etching, re-FPI etching, all machining operations, dimensional inspections. The supplier will also be required to process at least five componeats for rotating parts and two ‘components for static pars through the entire process for non destructive and destructive ‘examination, by the purchaser, for compliance with the requirements of Paragraphs 5 and 6. ‘Based on the rezults ofthe frst atcle inspection, the purchaser will approve the specific process for use atthe vendor. The process shall be ftozen and all subsequent production ‘actvies inthe ensurg purchase orders shall be carted out according to the fozen proces, ‘The vendor shall ebtin prior written approval from the purchaser for any change 10 the ‘process and, atthe purchaser's option, shall be required to prepare an addtional first article for approval wr Joti A - eSpecification No, EWR-GT-001/01-02 7.3 Documentation & Cectiation 7.3.1. Quality Control Tests In-process and final Quality Control tests shall be performed, as identified in Paragraph 6 ‘Results of all required tsting stall be recorded by serial number. A certified copy shal be given tothe purchasers representative before inspection. 73.2 Processing Records Processing records shal! be maintained in sufiient detail to indiate compliance with this specification and to allow traceability by lot. A copy of these rrreds shall be given tothe purchaser's represntatize before inspection. 73.3. Cenificate of Complianz: All processing. and quality control records shall be reviewed by the vendor to verily ‘compliance with tis specification and the purchase oréer. Any deviations shall be reported ‘immediately to the purewser and may be cause for rejection. A document certifying tat all aspocts of this specification and the purchase order have been met, stall be signed by the responsible vendor reprsentative and shall be presented to the purchaser upon delivery of the components. This docurent shall include: 8) Purchase order number 1b) Purchaser specification number ©) Purchaser drawing number 4) Component seril numbers an final disposition ) Heat treatment Is by serial number 1) A-copy ofall dccuments approving deviations from the requirements ‘ofthis specification 734 Records All process contol records and quality control test results shall be mainsined on file bythe ‘vendor for a period of seven years. Tis information shall be made available tothe purchaser ‘upon request 7.3.5. Final Report [A delivery of the comgonents, final report sll be issued which sal be containing: 2) All chemical andysis results including gas consents 1b) Ny results for eich melt, details of HIP, heat teatment eyes earied out ©) Metallographic end mechanical test results EPL. test results ©) Radiographic test results 1) A copy of the exficate of compliance 2) Marking and identification 1 ance and Dispos CComporents not meeting the requirements of this specification, the purchase order, and ow aSpecification No. EWR-GT-0O1/01-02 142 18 referenced drawings, sal be rejected and held for purchaser disposition, The purchaser shall be informed, in writing, ofthe nature ofthe non-conformance and the component feted Written authorization from the purchaser is required prior to the release of ay non. conforming parts, Al sorap pats shall be plainly labelled as scrap and be marked destructively in @ manner ‘which will prevent thei use Access “he pcs hall be alowed reassable acess ope componets tal tines aig the manufacturing proses. w gottt th‘Specification No, EWR-GT-OCLOI-02 TAnLE 1 ELEMENT Minimum (ut % oF wt. ppm) (et oF wtappm) Chrominm 157 163. Cobalt 8.0 9.0 ‘Aluminum + Ttaaiom 65 72 ‘Aluminm 32 37 “Titanium 32 a7 “Tungsten 24 28 ‘Molybdenum 15 20) ‘Tani 15 2.0, Nit 06 1 Carbon 0.09 0.13 Zirconium 0.03 0.06, Boron 0.007, 0.012 Iron _| 0.50) Phosphorus 0.01 Sulphur 0.0075, Silicon 030 Copper 0.10 Silver 5 ppm Bismuth 0.5 ppm Lead S ppm Manganese 0.20 Selenium 10 ppm ‘Magnesium 50 ppm Nickel al Dal, Pagetoot 11‘Specification No, EWR-GT-0O1/01-02 i "TABLE IL q Element ‘Maximo | (oom ‘Antimony 3 ‘Arsenic * Cadmium Gallium Trim : “Tellocium "Thal Page IF of 11Specification No, EWR-GT-OO1/01-02 ©) the grooeiah sil om the eter eon ntg all eter iti So ft roves nd al nes groove ZONE 2incws —°9)—_all aes nes ots put of ZONE a 0) ewe ics ofthe at ome srs ya ‘oven tac oe ZONE indy) allan onc ho a taf ZONE “MSUAL_& LOL ACCRITANCE CRITERION Fe oot st tionS, J 1) Nolin adsorp ot eer 2) Inictions Aum o es ae cnsdere w Better eae sti 2) leone sig apps on {Sa sie fw oll wn of si we fone ob taopeping nt sprite 4) None eee inden te peril ows NOTATING BLADES ZONE +O ses piel Zones = SaSnam mime fone 3tm0 anion STATIONARY VANES ZONE 125m main Jove? 1am ma foe) 20mm main 5) The maui umber fos eile any ows fo sil 25. Bac TEAR nalon tt pte os ino fis he bret dimen of he oy ret net 1) NowLlc inns which cine te bse ob aa on et pil 1) Posve inion se ot pei, 1) Indios wi eel he it dene sove ny be end asin eh Ln Tena enue design conto or 25, ofthe sl wal whichever sl, lene hal be se nd oma tome ed ies sal be» inimoa of 1 es th depth of he tem© Specification No. EWR-GT-001/01-02 napiocran ce CRITERION 1; No ne ection ve peraited 2! talent oon oer ot manne 3) ASTHC EID Rtas Ringo hl be se or nterettonof tns 9 Indetone we pit lows: ROTATING BLADES i ZOE - NO aerate peited i Zovts2a3 2 Gatto Mavi Sevey Level 2 *, Fordan Mitr Less Deae A "Gites @onner en) + Nobterndextons permite inal Acepance # STATIONARY VANES ZONED = cag tol Maou Severity Level 3 _SE Sines cay ~ Nove permed A sikags sponge Masa sve Level 1 ‘Shilage donee ~ Mast sre Level 1 ShinkageRzatscy- None pened 3 Folge Mater Less Dene AS pr Vinal Accepase war Ceri (Nonna el) ee othe ndson permite zone2 83 toes + nin See Level 4 5 Sivinkige cai’ Maton every eve 1 Shrinkage oo Maslow every Level + Shrokage desde - Mania seeriy Level 2 = Shinkge Gsmetry None pried + oragn Mat Last Dene = As por VisslFPLAccelance tes (Montene ony) No other indies petite 5) Spacing ints for us oles ss per Vinal PL aceptanc re ©) longed 1) es toe te ons linea aod ae not peri : wSeg oq wo yo>ydhy swosuaUID IY ~ 310 SOVg INTEL cat} SOV SNTGENL Ada sur eppem on ea a SIOV10 ONILVLOY SNINOZ SON | FIsrr Specification No, EWR-GT-O01001-02 APPENDIX It LOCATION OF METALLURGICAL TEST SPECIMENS ‘Anu of3 sess upturn bar ar equi fo euch open el ae enti sol: 2) One eas tae Mente a TI 1) Two Stet Rape tare Met ae “S152, ached Figures 3 an 4s ts etietione istry of pat Tues bs stall be michael fom th lesions e shown a th 07 rene in oer to ienity tend whieh way develop daring the manlitcnge ei rats of be eonpooent (cha pag ot Tei intended tat brs TI and °S1” be esd fom ae ade oo ve oter sud ed Uta bar 52 Be exceed rom hei sata Bee et ‘The components shal be sectioned “haiztally* ina fie the epprosimatemis-beight of he all, Specie Ioenlon and el of extiain lbw apeed wpb he ipl and puchS30W7G SNTLYLO8 SNOLLISS WILDS WLIW ONY Sava 1831 40 SNOLLVIOT € 3aS1d 3G INGAL VG AGM oe