This paper describes the manufacturing method and properties of a superalloy as a gas turbine blade material and a thermal barrier coating to protect it. The development process of superalloy and characteristics of each casting method were introduced. In particular, the single crystal superalloys were analyzed for creep and tensile properties with temperature according to chemical composition. In addition, the theories of creep life prediction models were summarized and comparative analysis was performed. Finally, the manufacturing processes of thermal barrier coatings were introduced, and the characteristics and effects of mechanical, thermal, and durability characteristics of each manufacturing process are described. We believe that this comprehensive review will help not only the gas turbine industry/community, but also material scientists, measurement physicists/engineers, and theorists interested in superalloys and high-temperature ceramics.

Higher fatigue and creep resistance at high temperatures are the essential properties for materials such as those used in gas turbines for power generation and aircraft turbines. Therefore, the nickel-based superalloy CMSX-4 was developed through single-crystal casting to satisfy these requirements. In this study, the CMSX-4 creep test results reported by previous researchers were used to mathematically derive an equation to estimate the amount of creep damage occurring under variable load conditions. In addition, low-cycle fatigue tests were performed, and the effect of creep damage occurring during fatigue on material failure was described.