Casting and Forging of Superalloys
S. Ganeshkumar, M. Ramesh, J. Maniraj
This chapter explores advancements in casting technologies and the development of superalloys, emphasizing their impact on modern engineering applications. Casting methods, such as sand, die, investment, centrifugal, and continuous casting, have evolved to offer improved precision and efficiency. Superalloys, including nickel-based, cobalt-based, and iron-based variants, exhibit exceptional high-temperature strength and corrosion resistance, crucial for aerospace, power generation, automotive, and chemical industries. Recent innovations, such as additive manufacturing and computational modelling, have further enhanced these materials and processes. Notably, nickel-based superalloys withstand temperatures up to 1,100 °C, and advanced casting techniques achieve dimensional tolerances within ± 0.1%. This chapter highlights the synergy between casting and superalloys, facilitating the production of complex, high-performance components. Future trends focus on sustainability, with efforts to reduce energy consumption and develop recyclable materials. This synergy drives progress in high-stress applications, promising significant advancements in industrial capabilities.
Keywords
Casting Technologies, Superalloys, Aerospace Applications, Additive Manufacturing, Corrosion Resistance
Published online 9/10/2025, 15 pages
Citation: S. Ganeshkumar, M. Ramesh, J. Maniraj, Casting and Forging of Superalloys, Materials Research Foundations, Vol. 178, pp 215-229, 2025
DOI: https://doi.org/10.21741/9781644903698-11
Part of the book on Superalloys
References
[1] N.M. Dawood, A.M. Salim, A review on characterization, classifications, and applications of superalloys, JUBES. 29 (2021) 53-62.
[2] G.R. Thellaputta, P.S. Chandra, C.S.P. Rao, Machinability of nickel-based superalloys: a review, Mater. Today Proc. 4 (2017) 3712-3721. https://doi.org/10.1016/j.matpr.2017.02.266
[3] I.G. Akande, O.O. Oluwole, O.S.I. Fayomi, O.A. Odunlami, Overview of mechanical, microstructural, oxidation properties and high-temperature applications of superalloys, Mater. Today Proc. 43, (2021) 2222-2231. https://doi.org/10.1016/j.matpr.2020.12.523
[4] W. Betteridge, S.W.K. Shaw, Development of superalloys, Mater. Sci. Technol. 3 (1987) 682-694. https://doi.org/10.1179/mst.1987.3.9.682
[5] H. Fecht, D. Furrer, Processing of nickel‐base superalloys for turbine engine disc applications, Adv. Eng. Mater. 2 (2000) 777-787. https://doi.org/10.1002/1527-2648(200012)2:12<777::AID-ADEM777>3.0.CO;2-R
[6] P.S. Gowthaman, S. Jeyakumar, A review on machining of high temperature aeronautics super-alloys using WEDM, Mater. Today Proc. 18 (2019) 4782-4791. https://doi.org/10.1016/j.matpr.2019.07.466
[7] A. Kracke, A. Allvac, Superalloys, the most successful alloy system of modern times-past, present and future, in: Proceedings of the 7th International Symposium on Superalloy. 718 (2010) pp. 13-50. https://doi.org/10.7449/2010/Superalloys_2010_13_50
[8] D.K. Ganji, G. Rajyalakshmi, Influence of alloying compositions on the properties of nickel-based superalloys: A review, in: H. Kumar, P. Jain (Eds.), Recent Advances in Mechanical Engineering, Select Proceedings of NCAME, 2019, pp. 537-555. https://doi.org/10.1007/978-981-15-1071-7_44
[9] A. Behera, A.K. Sahoo, S.S. Mahapatra, Application of Ni-based superalloy in aero turbine blade: A review, in: Proc. Inst. Mech. Eng. E: J. Process. Mech. Eng. 2023, 09544089231219104. https://doi.org/10.1177/09544089231219104
[10] Gudivada, G., & Pandey, A. K. Recent developments in nickel-based superalloys for gas turbine applications, J. Alloys Compds. (2023) 171128. https://doi.org/10.1016/j.jallcom.2023.171128
[11] F.L. VerSnyder, Keynote lecture superalloy technology today and tomorrow, in: E. Bachelet. (Eds.), High Temperature Alloys for Gas Turbines, Proceedings of a Conference held in Liège, Belgium, 4-6 October 1982 (pp. 1-49). Dordrecht: Springer Netherlands. https://doi.org/10.1007/978-94-009-7907-9_1
[12] D. Coutsouradis, A. Davin, M. Lamberigts, Cobalt-based superalloys for applications in gas turbines, Mater. Sci. Eng. 88 (1987) 11-19. https://doi.org/10.1016/0025-5416(87)90061-9
[13] J. Maniraj, F. Sahayaraj, J. Giri, T. Sathish, M.R. Shaik, Enhancing performance of prosopis juliflora fiber reinforced epoxy composites with silane treatment and syzygium cumini filler, J. Mater. Res. Technol. 31 (2024) 93-108. https://doi.org/10.1016/j.jmrt.2024.06.058
[14] R. Schafrik, R. Sprague, Superalloy technology-a perspective on critical innovations for turbine engines, Key Eng. Mater. 380 (2008), 113-134. https://doi.org/10.4028/www.scientific.net/KEM.380.113
[15] R. Darolia, Development of strong, oxidation and corrosion resistant nickel-based superalloys: critical review of challenges, progress and prospects, Int. Mater. Rev. 64 (2019), 355-380. https://doi.org/10.1080/09506608.2018.1516713
[16] Luo, A. A., Sachdev, A. K., & Apelian, D. (2022). Alloy development and process innovations for light metals casting, J. Mater. Process. Technol. 306, 117606. https://doi.org/10.1016/j.jmatprotec.2022.117606
[17] Sonar, T., Ivanov, M., Trofimov, E., Tingaev, A., & Suleymanova, I. (2024). An overview of microstructure, mechanical properties and processing of high entropy alloys and its future perspectives in aeroengine applications, Mater. Sci. Energy Technol. 7, 35-60. https://doi.org/10.1016/j.mset.2023.07.004
[18] A. Gloria, R. Montanari, M. Richetta, A. Varone, Alloys for aeronautic applications: State of the art and perspectives, Metals, 9 (2019) 662. https://doi.org/10.3390/met9060662
[19] H.A. Youssef, Machining of stainless steels and superalloys: traditional and nontraditional techniques, John Wiley & Sons, 2015. https://doi.org/10.1002/9781118919514
[20] A. Behera, A. Behera, Superalloys, in: Advanced Materials: An Introduction to Modern Materials Science, Springer, 2022, 225-261. https://doi.org/10.1007/978-3-030-80359-9_7
[21] A.F. Sahayaraj, M.T. Selvan, M. Ramesh, J. Maniraj, I. Jenish, K.J. Nagarajan, Extraction, purification, and characterization of novel plant fiber from tabernaemontana divaricate stem to use as reinforcement in polymer composites, Biomass Convers. Biorefin. (2024) 1-15. https://doi.org/10.1007/s13399-024-05352-4
[22] A.R. Paul, M. Mukherjee, D. Singh, A critical review on the properties of intermetallic compounds and their application in the modern manufacturing, Cryst. Res. Technol. 57 (2022) 2100159. https://doi.org/10.1002/crat.202100159
[23] Y.T. Tang, C. Panwisawas, J.N. Ghoussoub, Y. Gong, J.W. Clark, AA. Németh, R.C. Reed, Alloys-by-design: Application to new superalloys for additive manufacturing, Acta Mater. 202 (2021), 417-436. https://doi.org/10.1016/j.actamat.2020.09.023
[24] A.N. Jinoop, C.P. Paul, K.S. Bindra, Laser-assisted directed energy deposition of nickel superalloys: A review, Proc. Inst. Mech. Eng. Pt. L J. Mater. Des. Appl. 233 (2019), 2376-2400. https://doi.org/10.1177/1464420719852658
[25] J. Maniraj, M. Ramesh, S.G. Kumar, A.F. Sahayaraj, Introduction of biochar: sources, composition, and recent updates, in: A.K. Nadda, (Eds.), Biochar and its Composites: Fundamentals and Applications, Singapore: Springer Nature Singapore, 2023 pp. 1-17. https://doi.org/10.1007/978-981-99-5239-7_1
[24] H. Dai, A study of solidification structure evolution during investment casting of Ni-based superalloy for aero-engine turbine blades, Doctoral Dissertation, University of Leicester. 2009.
[25] G. Wu, C. Wang, M. Sun, W. Ding, Recent developments and applications on high-performance cast magnesium rare-earth alloys, J. Magnes. Alloy. 9 (2021), 1-20. https://doi.org/10.1016/j.jma.2020.06.021
[26] M. Javidani, D. Larouche, Application of cast Al-Si alloys in internal combustion engine components, Int. Mater. Rev. 59 (2014), 132-158. https://doi.org/10.1179/1743280413Y.0000000027
[27] S.F. Yang, S.L. Yang, J.L. Qu, J. Du, Y. Gu, P. Zhao, N. Wang, Inclusions in wrought superalloys: A review, J. Iron. Steel Res. Int. 28 (2021) 921-937. https://doi.org/10.1007/s42243-021-00617-y
[28] J. Du, X. Lv, J. Dong, W. Sun, Z. Bi, G. Zhao, B. Zhang, Research progress of wrought superalloys in China. Acta Metall. Sin. 55 (2019), 1115-1132.
[29] J. Maniraj, F.S. Arockiasamy, C.R. Kumar, D.A. Kumar, I. Jenish, I. Suyambulingam, I S. Siengchin, Machine learning techniques for the design and optimization of polymer composites: a review, in: E3S Web of Conferences, EDP Sciences, 428 (2023) pp. 02013. https://doi.org/10.1051/e3sconf/202342802013
[30] D. Ma, Novel casting processes for single-crystal turbine blades of superalloys, Front. Mech. Eng. 13 (2018), 3-16. https://doi.org/10.1007/s11465-018-0475-0
[31] S.K. Dewangan, A. Mangish, S. Kumar, A. Sharma, B. V. Kumar, A review on high-temperature applicability: a milestone for high entropy alloys, Eng. Sci. Technol. Int. J. 35 (2022) 101211. https://doi.org/10.1016/j.jestch.2022.101211
[32] M. Dada, P. Popoola, S. Adeosun, N. Mathe, High entropy alloys for aerospace applications. in: M.G. Bandpy, A.M. Aly (Eds.), Aerodynamics, Intech Open, 2019, 248.
[33] J. Bai, Y. Yang, C. Wen, J. Chen, G. Zhou, B. Jiang, F. Pan, Applications of magnesium alloys for aerospace: A review, J. Magnes. Alloy. 10 (2023) 3609-3619. https://doi.org/10.1016/j.jma.2023.09.015
[34] V. Dhinakaran, J. Ajith, A.F.Y. Fahmidha, T. Jagadeesha, T. Sathish, B. Stalin, Wire Arc Additive Manufacturing (WAAM) process of nickel-based superalloys – A review, Mater. Today Proc. 21 (2020), 920-925. https://doi.org/10.1016/j.matpr.2019.08.159
[35] A. Pineau, S.D. Antolovich, High temperature fatigue of nickel-base superalloys-a review with special emphasis on deformation modes and oxidation, Eng. Fail. Anal. 16 (2009) 2668-2697. https://doi.org/10.1016/j.engfailanal.2009.01.010
[36] K.P. Boopathiraja, R. Ramamoorthi, P. Hariprasad, F.S. Arockiasamy, Enhancing microstructural and mechanical properties of magnesium AZ31 matrix composites through friction stir processing incorporating silicon carbide, titanium carbide, and graphite particles, Mater. Res. Express. 11 (2024), 076507. https://doi.org/10.1088/2053-1591/ad5cdc
[37] M.V. Raja, K. Manonmani, A.F. Sahayaraj, Investigation on electrical discharge machining parameters of aluminium7075/boron carbide/titanium diboride hybrid composites by grey relational analysis, Proc. Natl. Acad. Sci. India A: Physical Sciences, (2024) 1-13. https://doi.org/10.1007/s40010-024-00879-7
[38] S. Ravichandran, R. Duraiswamy, F.S. Arockiasamy, Tool and formability multi-response optimization for ultimate strength and ductility of AA8011 during axial compression. Adv. Mech. Eng. 14 (2022), 16878132221131731. https://doi.org/10.1177/16878132221131731
[39] B.A. Kumar, M.M. Krishnan, A.F. Sahayaraj, M.R.A. Refaai, G. Yuvaraj, D. Madhesh, H.L. Allasi, Characterization of the aluminium matrix composite reinforced with silicon nitride (AA6061/Si3N4) synthesized by the stir casting route, Adv. Mater. Sci. Eng. 1 (2022) 8761865. https://doi.org/10.1155/2022/8761865
