Reduction of the fuel consumption and emission of NOX and CO2 by jet engines is a priority of the ACARE SRA 2020 objectives. The development of an environmentally friendly aircraft engine (SAGE1) considers using lightweight and efficient turbine components. Within the objectives of open rotor development in SAGE1, activities are underway to develop new technologies for rotating structures. The rotating structure transmits the torque generated by the engine to the propellers and is subjected to the high temperature exhaust gas from the turbine. It is likely that frames will be made as a weld assembly consisting of cast parts in a newly developed y’ strengthened nickel based superalloy. However, it is a challenge to cast these alloys because they were primarily developed in wrought form. Currently, cast versions of low content y’ strengthened Ni alloys are widely investigated however failure analysis and damage mechanisms are not fully explored.

Thus the aim of this project was complex failure analysis of a new alloy which is an enabler material for manufacturing turbine components exposed at high temperature. In order to conduct a comprehensive investigation of damage mechanism the following objectives had been defined:

• optimizing the casting process parameters and heat treatment of alloy for a range of microstructures;
• experimental studies of mechanical behaviour of newly developed alloy with different grain size under different loading and temperature regimes during monotonous and fatigue tests;
• determination and characterisation of damage mechanisms by advanced microstructural characterisation techniques.

The consortium consisted of technical university (WUT) and two certified, modern research centres equipped with unique devices providing high quality testing services, which offer new solutions to contemporary aviation (IoA and KIMAB). Such a structured consortium provided complex expertise abilities of basic research studies and experimental trials.