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Schematic Diagram of Traditional Mold Casting Process for High-Temperature Master Alloys

Current Manufacturing Process for High-Temperature Alloy Master Alloys

High-temperature alloys, also known as "superalloys," are a class of metallic materials based on iron, nickel, or cobalt. They are capable of long-term service at temperatures above 600°C under applied stress. These alloys offer a combination of exceptional properties, including high-temperature strength, excellent oxidation and hot corrosion resistance, good fatigue performance, and fracture toughness.

A "master alloy" refers to the refined material (typically supplied in bar form) used as feedstock for remelting and casting. Its chemical composition is precisely controlled according to customer specifications.

Currently, the vacuum induction melting (VIM) followed by metal mold casting process is widely used for producing high-temperature alloy master alloys, as illustrated in the diagram. In this conventional casting process, the refined molten metal is poured through a launder and finally into a metal mold, where it solidifies into the desired shape. This manufacturing method enables the production of high-temperature alloy master alloys with precise chemical composition. Through techniques such as controlled melting parameters, ceramic filtration, and optimized mold design, ingots with excellent metallurgical quality and superior performance can be achieved.

High-temperature alloy master alloys exhibit excellent high-temperature strength and creep resistance. Taking K418 superalloy master alloy as an example, after precise composition control and clean melting practices, its chemical composition must meet the requirements specified in Table 1 (in accordance with GB/T14992, GJB5512.1, and HB7763). Furthermore, after the master alloy is remelted and investment cast into test bars, the mechanical properties must satisfy the requirements listed in Table 2.

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Table 1 Chemical Composition of K418 Alloy (wt.%)

Element C Mo Cr Al Zr Ti B
Content(%) 0.08~0.16 3.80~4.80 11.50~13.50 5.50~6.40 0.060~0.150 0.50~1.00 0.008~0.020
Element Nb Fe Mn Si S P O
Content(%) 1.80~2.50 ≤1.00 ≤0.50 ≤0.50 ≤0.010 ≤0.015 ≤15ppm
Element N Pb Sb As Sn Bi Ni
Content(%) ≤35ppm ≤0.0005 ≤0.001 ≤0.001 ≤0.001 ≤0.00005 Bal.

Table 2: Supply Technical Standards for K418 Alloy

Standard Number Variety Sampling Tensile Properties Durability Performance
θ/℃ σ b/MPa σ po.2/MPa δ5/ ψ/% θ/℃ σ/MPa T/h δs/
≥ ≥
GJB5515.1① Master Alloy Precision-cast test bar in as-cast condition 20  755  686  3.0  一 750  608  40  3.0 
800  755  一 4.0  6.0  800  490  45  3.0 
HB7763② Master Alloy Precision-cast test bar in as-cast condition 20  755  686  3.0  - 750  608  40  3.0 
800  755  一 4.0  6.0  800  490 45  3.0 
①Stretching and endurance can be tested at one temperature. If the endurance performance is not qualified, it can be retested at 800 ℃, 471MPa, and a fracture time of not less than 80 hours.
  Every 10 furnaces should be selected for a long-term tensile test, and the δ 5 and ψ values after fracture should not be used as the basis for rejection.
②Tensile and stress rupture tests may be conducted at a single selected temperature. For every 10 heats produced, one heat shall be subjected to stress rupture testing until fracture, with actual measurements taken for percentage elongation (δ5) and percentage reduction of area (ψ).


Grade K417 K418 K419 K438 K444 K452 K4169
Chemical composition
(weight%)		 C 0.13  0.08  0.09  0.10  0.04  0.07  0.02 
0.22  0.16  0.14  0.20  0.08  0.14  0.08 
Cr 8.50  11.50  5.50  15.70  15.40  20.00  17.00 
9.50  13.50  6.50  16.30  16.30  21.80  21.00 
Mn 0.50  0.50  0.50  0.20  0.30  0.30  0.35 
Mo 2.50  3.80  1.70  1.50  1.60  0.30  2.80 
3.50  4.80  2.30  2.00  2.30  0.90  3.30 
Mb 一 1.80  2.50  0.60  0.10  0.15  4.40 
2.50  3.30  1.10  0.30  0.35  5.40 
Ta 一 一 一 1.50  一 一 0.10 
2.00 
Ni 56.78  69.44  55.76  58.19  54.60  52.70  50.00 
64.92  76.75  63.43  63.94  60.90  60.90  55.00 
Co 14.00  11.00  8.00  10.00  10.30  1.00 
16.00  13.00  9.00  11.00  12.00 
Ti 4.50  0.50  1.00  3.00  4.20  3.10  0.65 
5.00  1.00  1.50  3.50  5.00  3.90  1.15 
V 0.60  一 0.10  一 一 一 一
0.90 
W 一 一 9.50  2.40  4.70  3.00  一
10.50  2.80  5.90  4.00 
Zr 0.05  0.06  0.03  0.05  一 一 0.05 
0.09  0.15  0.08  0.15 
Fe 1.00  1.00  0.50  0.50  0.50  0.50  11.57 
24.83 
Al 4.80  5.50  5.20  3.20  2.80  2.10  0.30 
5.70  6.40  5.70  3.70  3.20  2.90  0.70 
Others 一 一 Cu0.40 一 Hf0.20-0.40 B0.01-0.02 Cu0.30
B0.06-0.10 Zr0.02-0.06
Mechanical properties of alloy materials Temperature(°C) 750  800  950  800  900  一 Room temperature
Tensile Strength(σb/
Mpa)		 686  755  700  836  一 一 965 
Durability Performance(σ/
Mpa)		 一 490  一 365  274  一 550 
Elongation(δ
1%)		 2.5  4  6  16.6  一 一 30 
Grade GH2132 GH3039 GH3044 GH3128 GH4133 GH4169 GH4220 GH4708
Chemical Composition
(weight%)		 C 0.08  0.08  0.10  0.05  0.07  0.08  0.08  0.05 
0.10 
Cr 13.50  19.00  23.50  19.00  19.00  17.00  9.00  17.50 
16.00  22.00  26.50  22.00  22.00  21.00  12.00  20.00 
Ni 24.00  69.42  50.20  56.59  70.22  50.00  46.41  58.12 
27.00  77.60  63.20  65.20  76.65  55.00  60.65  70.05 
Co 一 一 一 一 一 1.00  14.00  0.05 
15.50 
W 一 一 13.00  7.50  一 一 5.00  5.50 
16.00  9.00  6.50  7.50 
Mo 1.00  1.80  1.50  7.50  一 2.80  5.00  4.50 
1.50  2.30  9.00  3.30  7.00  6.00 
Al 0.40  0.35  0.50  0.40  0.70  0.30  3.90  1.90 
0.75  0.80  1.20  0.70  4.80  2.30 
Ti 1.75  0.35  0.30  0.40  2.50  0.75  2.20  1.00 
2.30  0.75  0.70  0.80  3.00  1.15  2.90  1.40 
Fe 50.17  3.00  4.00  0.20  1.50  11.92  3.00  4.00 
58.65  24.40 
Nb 一 0.90  一 一 1.15  4.75  一 一
1.30  1.65  5.50 
V 0.10  一 一 一 一 一 0.25  一
0.50  0.80 
B 0.00  一 一 0.01  一 0.01  一 0.01 
0.01 
Zr 一 0.06  一 一 一
Ce 一 一 一 一 0.01  一 一 0.03 
Mn 一 一 0.50  0.50  0.35  0.35  0.50  0.50 
Mechanical properties of alloy materials Temperature(°C) Room temperature Room temperature 一 一 Room temperature 650  一 一
Tensile Strength(σb/
Mpa)		 930  635  一 一 750  1000  一 一
Yield Strength(δs/
Mpa)		 590  一 一 一 1080  一 一 一
Elongation(δ
1%)		 15  3  一 一 16  15  一 一
Grade C Cr Mn Mo Nb Ta Ni  Co Ti Hf W Zr Fe Al Others
DD406 0.001
0.04		 3.80
4.80		 0.15  1.50
2.50		 1.20  6.00
8.50		 54.70
66.34		 8.50
9.50		 0.10  0.05
0.15		 7.00
9.00		 0.10  0.30  5.20
6.20		 Re1.6~2.4
DD407 0.007  7.80
8.30		 0.01  2.10
2.40		 0.15  3.30
3.70		 65.7
69.4		 5.00
6.00		 1.80
2.20		 0.0075  4.80
5.20		 0.0075  0.20  5.80
6.10		 -
DD408 0.03  15.50
16.50		 0.15  一 一 0.70
1.20		 49.62
55.50		 8.00
9.00		 3.60
4.20		 一 5.60
6.40		 0.007  0.50  3.60
4.20		 Al+Ti
7.5~7.9
Grade C   Cr Mn Mo Nb Ta   Ni Co Ti V W Zr Fe Al Others
DZ404 0.10
0.16		  9.00
 10.00		 0.50  3.50
4.20		 - - 62.16
69.58		 5.50
6.50		 1.60
2.20		 - 5.10
5.80		 0.02  1.00  5.60
6.40		 -
DZ405 0.07
0.15		 9.50
11.00		 0.50  3.50
4.20		 一 一 58.5
65.92		 9.50
10.50		 2.00
3.00		 一 4.50
5.50		 0.10  一 5.00
6.00		 -
DZ408 0.07
0.10		  8.00
 8.70		 0.10  0.40
0.60		 0.10  2.80
3.30		 59.03
63.27		 9.00
10.00		 0.60
0.90		 0.10  9.30
9.70		 0.005
0.02		 0.20  5.25
5.75		 Hf1.30~1.70
Re0.10
DZ411 0.07
0.12		 13.50
14.30		 - 1.30
1.70		 一 2.50
3.10		 58.28
62.73		 9.00
10.00		 4.60
5.20		 一 3.50
4.10		 一 一 2.80
3.40		 Al+Ti≥7.80
DZ417G 0.13
0.22		  8.50
 9.50		 0.20  2.50
3.50		 - - 63.53
70.35		 9.00
11.00		 4.10
4.70		 0.60
0.90		 - 一 0.5  4.80
5.70		 -

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