Single-crystalline superalloy CMSX-4 is studied in the as-cast state and after heat treatment, with material being taken from turbine blade castings. The effect of the heat treatment on the defect structure of the root area near the selector/root connection is emphasized. Multiscale analysis is performed to correlate results obtained by X-ray topography and positron annihilation lifetime spectroscopy (PALS). Electron microscopy observations were also carried out to characterize the inhomogeneity in dendritic structure. The X-ray topography was used to compare defects of the misorientation nature, occurring in as-cast and treated states. The type and concentration of defects before and after heat treatment in different root areas were determined using the PALS method, which enables voids, mono-vacancies, and dislocations to be taken into account. In this way, differences in the concentration of defects caused by heat treatment are rationalized.

An analysis of the defects in the vicinity of the selector–root connection plane occurring during the creation of single-crystalline turbine blades made of CMSX-6 Ni-based superalloy was performed. X-ray diffraction topography, scanning electron microscopy, and positron annihilation lifetime spectroscopy were used. Comparing the area of undisturbed axial growth of dendrites to the area of lateral growth concluded that the low-angle boundaries-like (LAB-like) defects were created in the root as a result of unsteady-state lateral growth of some secondary dendrite arms in layers of the root located directly at the selector–root connection plane. Additional macroscopic low-angle boundaries (LABs) with higher misorientation angles were created as a result of concave curvatures of liquidus isotherm in platform-like regions near selector–root connections. Two kinds of vacancy-type defects, mono-vacancies and vacancy clusters, were determined in relation to the LABs and LAB-like defects. Only mono-vacancies appeared in the areas of undisturbed axial growth. Reasons for the creation of macroscopic LABs and LAB-like defects, and their relationships with vacancy-type defects were discussed.

The thin-walled airfoil areas of as-cast single-crystalline turbine blades made of CMSX-4 superalloy were studied. The blades were produced by the industrial Bridgman technique at withdrawal rates of 2, 3 and 4 mm/min. The angle between the [001] crystallographic direction and blade axis, related to the primary orientation, was defined by the Ω-scan X-ray diffraction method at points on the camber line located near the tip of an airfoil and at points of a line located in parallel and near the trailing edge. Additionally, primary crystal orientation was determined by Laue diffraction at the selected points of an airfoil. The influence of mould wall inclination on the primary crystal orientation of the thin-walled areas is discussed. The effect of change in the [001] crystallographic direction, named as “force directing”, was considered with regard to the arrangement of primary dendrite arms in relation to the trailing edge and the camber line. It was stated that when the distance between the mould walls is less than the critical value of about 1.5 mm the “force directing” increases as the distance between the walls of the mould decreases. The effect may be controlled by selecting an appropriate secondary orientation using a seed crystal in the blade production process. The model of dendrite interaction with the mould walls, including bending and “deflection”, was proposed.

The variation of the crystal orientation and the dendrite array generated in the root of the single-crystalline (SX) turbine blades made of CMSX-4 superalloy were studied. The blades with an axial orientation of the [001] type were solidified by the industrial Bridgman technique using a spiral selector at a withdrawal rate of 3 mm/min. The analysis of the crystal orientation and dendrite arrangement was carried out using scanning electron microscopy, X-ray diffraction topography, and Laue diffraction. It was found that the lateral growth of such secondary dendrite arms, which are defined as “leading” and grow in the root at first, is related to the rotation of their crystal lattice, which is the reason for creation of the low-angle boundary (LAB) type defects. The primary crystal orientation of the selector extension (SE) area determines the areas and directions of the lateral growth of the leading arms. Additionally, it was found that in the SE areas of the root, near the connection with the selector, the spatial distribution of the [001]γ′ crystallographic direction has a complex wave-like character and may be related to the shape of the crystallization front.

Quasicrystalline as well as crystalline faceted single grains of four phases were obtained during directional crystallisation of an Al–Cu–Fe alloy by the Bridgman technique. The monoclinic λ phase, Al₁₃(Cu, Fe)₄, dominating at high temperatures formed single-crystal lamellae 0.5 mm to 1 mm thick. A second type of attractive morphological form exhibiting flux dissolution terraces was observed on spherical single crystals of β phase Al(Fe, Cu). Rectangular, hexagonal and octagonal shaped dissolution terraces were revealed at the positions of two-, three- and four-fold symmetry axes, respectively. A single quasicrystalline ψ phase, Al₆Cu₂Fe, exhibited icosahedral symmetry with growth forms of a dodecahedron with pentagonal facets. The flux dissolution of the β phase apparently plays an essential role in a peritectic reaction leading to quasicrystalline ψ phase formation. Polygonal single grains of ω phase Al₇Cu₂Fe exhibiting tetragonal symmetry formed the fourth type of thermodynamically stable growth forms. Single grains of the ω phase crystallised in the form of pellets with an octagonal cross-section. The growth morphology of the stable phases was investigated by scanning electron microscopy. The chemical composition of the growth forms described was confirmed by X-ray microanalysis using a scanning electron microscope, whereas the phase composition was determined using electron selected area diffraction and X-ray powder diffraction.