R. C. Benn, S. G. Song, J. R. Irish, UTRC, East Hartford, CT

Summary:

Replacement of dense alloys that perform at high temperatures, where conventional aluminum alloys degrade, is a major opportunity for higher temperature aluminum alloys. The weight reduction and potential cost reductions in materials and manufacturing are prime drivers. The real challenge has long been to develop the high temperature property improvements in specific alloy designs that can be converted into very complex shapes by low cost processes, i.e. casting. In recent years, significant improvements have been made in the casting technology of aluminum-based alloys through controlled solidification processes. Hence, the objective of this work is to develop a family of Cast High Temperature Aluminum (CHTA) alloys for gas turbine applications in the range of 150 ºC (~300 ºF) to 350 ºC (~650 ºF). CHTA alloys have the potential to replace denser (or less corrosion resistant) cast alloys and also complex fabricated wrought structures. This presentation will address some of the alloy design and structural aspects, compare property levels with other alloys, and describe selected aerospace applications.