The service performance of single crystal blades depends on the crystal orientation. A grain selection method assisted by directional columnar grains is studied to control the crystal orientation of Ni-based single crystal superalloys. The samples were produced by the Bridgman technique at withdrawal rates of 100 μm/s. During directional solidification, the directional columnar grains are partially melted, and a number of stray grains are formed in the transition zone just above the melt-back interface. The grain selected by this method was one that grew epitaxially along the un-melted directional columnar grains. Finally, the mechanism of selection grain and application prospect of this grain selection method assisted by directional columnar grains is discussed.

This study investigates the influence of solidification conditions on the high-cycle fatigue (HCF) behavior of a second-generation DD6 single-crystal superalloy. Single-crystal bars with a [001] orientation were prepared using the high-rate solidification (HRS) and liquid-metal cooling (LMC) techniques under various pouring temperatures. The HCF performance of the heat-treated alloy was subsequently evaluated at 800 °C using rotary bending fatigue tests. The results demonstrate that increasing the pouring temperature effectively reduced the content and size of microporosity in the HRS alloys. At an identical pouring temperature, the LMC alloy exhibited a significant reduction in microporosity, with its content and maximum pore size being only 44.4% and 45.8% of those in the HRS alloy, respectively. Consequently, the HCF performance was enhanced with increasing pouring temperature for the HRS alloys. The LMC alloy outperformed its HRS counterpart processed at the same temperature, showing a 9.4% increase in the conditional fatigue limit (at 10⁷ cycles). Microporosity was identified as the dominant site for HCF crack initiation at 800 °C. The role of γ/γ′ eutectic in crack initiation diminished or even vanished as the solidification conditions were optimized. Fractographic analysis revealed that the HCF fracture mechanism was quasi-cleavage, independent of the solidification conditions. Under a typical stress amplitude of 550 MPa, the deformation mechanism was characterized by the slip of a/2 dislocations within the γ matrix channels, which was also unaffected by the solidification conditions. In conclusion, optimizing solidification conditions, such as by increasing the pouring temperature or employing the LMC process, enhances the HCF performance of the DD6 alloy primarily by refining microporosity, which in turn prolongs the fatigue crack initiation life.