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NASA's new Ni-based superalloy uses a powder metallurgy (PM) composition that inhibits the deleterious gamma-prime to gamma-phase transformation along stacking faults during high temperature creep deformation. Ni-base superalloys have excellent high temperature properties, mostly due to the presence of coherent precipitates. At higher temperatures, these precipitates are defeated by the diffusional shear dislocations producing intrinsic and extrinsic faults. Recent studies have found that, during deformation of turbine disk alloys at high temperature, Co, Cr, and Mo segregate to these faults (removing Ni and Al) inside the strengthening precipitates of these alloys. This represents a local phase transformation from the strengthening precipitate to the weaker matrix phase. Therefore, this elemental segregation significantly weakens the ability of a precipitate to withstand further deformation, producing faster strain rates in the alloy at higher temperatures. This invention presents a solution to prevent this type of segregation along these two faults to improve the creep properties of turbine disks and similar Ni-based alloys. By alloying a specific amount of eta phase formers (Ti, Ta, Nb, and Hf), the phase transformation to can be eliminated along 2-layer extrinsic stacking faults (SESFs) in precipitates without precipitating bulk eta phase. Also, by adding a certain amount of D019 formers (Mo and W), the phase transformation to can be mitigated along 1-layer intrinsic stacking faults (SISFs) without producing bulk sigma phase. This alloy composition incorporates both strengthening methods for use in jet turbine disks, though the composition has applications in other high-stress and/or high-temperature environments as are found in power plants, space launch systems, and other critical structural applications.

The manufacturing process, building on techniques showcased in LEW-TOPS-151, employs a novel acoustic mixing technique to coat spherical C103 powder particles with a uniform distribution of sub-200 nanometer yttria particles. During laser powder bed fusion additive manufacturing, layer-by-layer remelting disperses these yttria particles uniformly throughout the component microstructure. This eliminates the expensive, time-consuming mechanical alloying steps traditionally required for ODS alloys while enabling near-net-shape fabrication of complex geometries. Performance testing demonstrates substantial improvements: GRC103y exhibits double the yield strength at 800°C and 1.5x the yield strength at 1,400°C compared to baseline C103. The alloy also shows superior thermal stability: after one hour at 1,500°C, GRC103y retains 90% of its room temperature strength compared to only 67% for C103. Preliminary creep testing at 1,300°C and a stress of 50 MPa indicates significant improvements in creep resistance by 2539 times over baseline C103. Furthermore, GRC103y maintains excellent formability, allowing manufacturers to use traditional fabrication methods when desired. While NASA originally developed GRC103y for rocket propulsion and hypersonic vehicle applications, the alloy offers value across multiple industries. Aerospace companies can achieve weight savings or push systems to higher temperatures, while the alloy's compatibility with commercial oxidation coatings makes it suitable for environments requiring oxidation protection. GRC103y is currently available for patent licensing.